Maintenance Manual Ottawa 4x2, 6x4

Table of Contents

Foreword 1 Introduction 3 The Ottawa Terminal Tractor ............................................................................................ 3 Description ........................................................................................................ 3 Safety Summary ................................................................................................................ 4 Hazardous Conditions ....................................................................................... 4 Diesel Fuel Requirements ................................................................................................. 6 Precautions ....................................................................................................... 6 Emergency Starting ........................................................................................................... 7 Precautions ....................................................................................................... 7 Jump Starting Instructions ................................................................................. 7 Vehicle Towing .................................................................................................................. 9 Precautions ....................................................................................................... 9 Front End Towing (Front Wheels Off the Ground) ............................................ 9 Front End Towing (All Wheels On the Ground) ............................................... 10 Rear End Towing ............................................................................................ 10 Vehicle Modifications ...................................................................................................... 10 11 Vehicle Identification Location/Description ........................................................................................................ 11 Identification Plate ........................................................................................... 11 Certification Label ........................................................................................... 11 Serial Number ................................................................................................. 11 Engine Serial Number ..................................................................................... 11 Description and Operation 13 Cab/Deck ........................................................................................................................ 13 Construction ............................................................................................................... 13 Cab Mounting and Suspension .................................................................................. 14 Cab Tilting .................................................................................................................. 15 Seating ....................................................................................................................... 17 Instrument Panel Gauges, Controls and Indicators .................................................... 17 Electrical Equipment .................................................................................................. 19 Heating/Air Conditioning ............................................................................................ 19 Accessories and Options ........................................................................................... 19 Chassis ........................................................................................................................... 20 Frame ........................................................................................................................ 20 Powertrain .................................................................................................................. 22 Vehicle Suspension Including Otto-Ride .................................................................... 22 Air System and Brakes .............................................................................................. 24 Brake System ............................................................................................. 24 Anti-lock Brake System (Optional) ............................................................. 28 Automatic Traction Control (Optional) ........................................................ 29 Hydraulic System ....................................................................................................... 29 System Overview ....................................................................................... 29 Boom Components .................................................................................... 30 Cab Tilt Components ................................................................................. 31 Power Steering Components ..................................................................... 32 Fuel System ............................................................................................................... 33 35 Component Location Chassis/Cab, Left Side .................................................................................................... 35 Ottawa Series, Left Side (4x2 chassis shown) ................................................ 35 Chassis/Cab, Right Side ................................................................................................. 37 Ottawa Series, Right Side (4x2 chassis shown) .............................................. 37 Chassis/Cab, Front/Rear ................................................................................................. 38 Ottawa Series, Front/Rear (4x2 chassis shown) ............................................. 38 Chassis, Plan View ......................................................................................................... 39 Ottawa Series, Plan View (4x2 chassis shown) .............................................. 39

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Table of Contents

Diagnostic Procedures 41 Safety .............................................................................................................................. 41 Summary ......................................................................................................... 41 Electrical .......................................................................................................................... 41 Guide to Troubleshooting ................................................................................ 41 Basic Gauge Diagnostic Procedure ................................................................ 41 Engine ......................................................................................................................... 43 Starting and Charging ................................................................................ 43 Cab Instruments .......................................................................................................... 44 Low Air Warning ......................................................................................... 44 Ammeter ..................................................................................................... 45 Coolant, Oil and Fuel Gauges .................................................................... 46 Hourmeter .................................................................................................. 47 Speedometer .............................................................................................. 48 Tachometer ................................................................................................ 49 Voltmeter .................................................................................................... 50 Lighting ....................................................................................................................... 51 Backup Light and Alarm, Flood Light ......................................................... 51 Beacon Light .............................................................................................. 52 Clearance, Marker and Tail Lights ............................................................. 53 Daytime Running Lights ............................................................................. 54 Dome Light ................................................................................................. 55 Headlights .................................................................................................. 55 Trailer Auxiliary Power ............................................................................... 56 Transmission Shifter/Fifth-Wheel Control and Panel Lighting .................... 57 Turn Signal, Brake Lights and Emergency Flasher .................................... 58 Accessories and Options ............................................................................................ 59 Accessory Relay ......................................................................................... 59 Air Dryer ..................................................................................................... 59 Cab Tilt Pump ............................................................................................. 60 Heater/Air Conditioning (Optional) ............................................................. 61 Horn ............................................................................................................ 62 Mirrors (Heated/Motorized) ........................................................................ 63 Radio (Optional) ......................................................................................... 64 Windshield Washer .................................................................................... 65 Windshield Wipers ...................................................................................... 66 Hydraulic ......................................................................................................................... 67 Boom ............................................................................................................... 67 Cab Tilt ............................................................................................................ 68 Power Steering ................................................................................................ 69 Mechanical ...................................................................................................................... 70 Brakes ............................................................................................................. 70 Pneumatic ....................................................................................................................... 73 Brakes — Air System ...................................................................................... 73 Cab Air Suspension ......................................................................................... 76 Structural ......................................................................................................................... 77 Chassis ............................................................................................................ 77 Scheduled Maintenance 81 Checklists ........................................................................................................................ 81 Lubrication Points ............................................................................................ 81 Daily Inspection Checklist ............................................................................... 82 Every 250 Hours of Operation ......................................................................... 83 Every 500 Hours of Operation ......................................................................... 83 Every 1,000 Hours of Operation ...................................................................... 83 Every 2,000 Hours of Operation ...................................................................... 83

Table of Contents

Preventive Maintenance Forms ....................................................................... 84 Preventive Maintenance Technique ................................................................ 86 Cab Interior ..................................................................................................... 87 Cab Down — Exterior ...................................................................................... 88 Cab Up ............................................................................................................ 89 Under Vehicle .................................................................................................. 91 Chassis ........................................................................................................... 92 Lubrication ....................................................................................................... 93 Test Drive ........................................................................................................ 94 Repair Procedures 95 Chassis ........................................................................................................................... 95 Frame Damage ........................................................................................................... 95 Damage Analysis ....................................................................................... 95 Making Reinforcements .............................................................................................. 95 General Information ................................................................................... 95 Attachment ................................................................................................. 96 Repairing Cracks in Steel Rails or Cross Members .................................................... 97 Types of Cracks ......................................................................................... 97 Front Springs and Pins ............................................................................................... 98 Springs and Pins Removal ......................................................................... 98 Springs and Pins Installation ...................................................................... 99 Cab/Deck ...................................................................................................................... 100 Air Ride Suspension (Three-Point) ........................................................................... 100 Cab Suspension Assembly Removal ....................................................... 100 Cab Suspension Assembly Installation .................................................... 101 Air Ride Level Adjustment ........................................................................ 101 Leveling Valve .......................................................................................................... 102 Valve Operation Check ............................................................................ 102 Shock Absorbers ...................................................................................................... 103 Shock Removal ........................................................................................ 103 Shock Installation ..................................................................................... 103 Cab Latch Bar Plate .................................................................................................. 104 Latch Bar Plate Adjustment ...................................................................... 104 Cab Tilt Cylinder ....................................................................................................... 105 Cylinder Removal ..................................................................................... 105 Cylinder Installation .................................................................................. 106 Cab Tilt Pump and Motor .......................................................................................... 107 Pump and Motor Removal ....................................................................... 107 Pump and Motor Installation .................................................................... 107 Relief Pressure Adjustment (2001 and Newer Trucks) ............................ 108 Cab Pivot Bushing .................................................................................................... 108 Pivot Bushing Removal ............................................................................ 108 Pivot Bushing Installation ......................................................................... 110 Rear Door ................................................................................................................. 111 Rear Door Adjustment .............................................................................. 111 Specifications 113 Standard Vehicle Data .................................................................................................. 113 Ottawa Series Terminal Tractor .................................................................... 113 Hydraulic System .......................................................................................................... 115 Ottawa Series 4x2 and 6x4 ........................................................................... 115 Fluids, Lubricants and Sealants .................................................................................... 116 Ottawa Series 4x2 and 6x4 ........................................................................... 116 Fastener Torque Values ................................................................................................ 118 Ottawa Series 4x2 and 6x4 ........................................................................... 118 Schematics 119

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Table of Contents

Air System Circuits ........................................................................................................ 119 Air Brakes ................................................................................................................ 119 Components ............................................................................................. 119 Air Brake System with ABS ........................................................................... 120 Air Brake System without ABS ...................................................................... 122 Cab Seating ............................................................................................................. 124 Air Lines — Driver's Seat ......................................................................... 124 Cab Suspension ....................................................................................................... 125 Air Lines — Cab Suspension ................................................................... 125 Fifth-Wheel Coupling ............................................................................................... 126 Air Lines — Fifth-Wheel Latch .................................................................. 126 Hydraulic System Circuits ............................................................................................. 127 Hydraulic Systems ......................................................................................... 127 Cab Tilt ..................................................................................................................... 127 Hydraulic Lines — Cab Tilt ....................................................................... 127 Fifth-Wheel Boom .................................................................................................... 128 Hydraulic Lines — Fifth-Wheel Boom ...................................................... 128 Power Steering ........................................................................................................ 129 Hydraulic Lines — Power Steering ........................................................... 129 Electrical System Circuits .............................................................................................. 130 Starting and Charging .............................................................................................. 130 Starting and Charging Circuit ................................................................... 130 Cab Accessory Components ................................................................................... 131 Wire Color Codes ..................................................................................... 131 Anti-lock Braking System (ABS) ............................................................... 132 Heater and Air Conditioning ..................................................................... 132 Horn .......................................................................................................... 133 Mirrors ...................................................................................................... 134 Radio (Optional) ....................................................................................... 136 Windshield Washer (Optional) .................................................................. 138 Windshield Wiper ..................................................................................... 139 Cab Instrumentation ................................................................................................. 140 Air Pressure Gauge Lighting .................................................................... 140 Ammeter (Optional) .................................................................................. 141 Engine Coolant Temperature Gauge ....................................................... 142 Engine Hourmeter .................................................................................... 143 Engine Oil Pressure Gauge ...................................................................... 144 Fuel Gauge ............................................................................................... 146 Low Air Warning Alarm ............................................................................. 147 Speedometer (Optional) ........................................................................... 148 Tachometer (Optional) ............................................................................. 149 Transmission Oil Temperature Gauge ..................................................... 150 Voltmeter .................................................................................................. 152 Chassis Circuits ....................................................................................................... 153 Air Dryer (Optional) .................................................................................. 153 Cab Tilt Pump ........................................................................................... 154 Lighting Circuits (Cab and Chassis) ......................................................................... 155 Backup Light and Alarm ........................................................................... 155 Beacon/Strobe Light ................................................................................. 156 Clearance Lights ...................................................................................... 157 Daytime Running Lights (Optional) .......................................................... 158 Dome Light ............................................................................................... 159 Fifth-Wheel Control .................................................................................. 160 Flood Light ................................................................................................ 160 Headlights ................................................................................................ 161

Table of Contents

Marker Lights ........................................................................................... Panel Lighting .......................................................................................... Strobe Light .............................................................................................. Tail Lights ................................................................................................. Trailer Auxiliary Power ............................................................................. Transmission Shifter, Fifth-Wheel Control and Panel Lighting ................. Turn Signal, Tail, Brake Lights and Emergency Flasher ..........................

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161 161 161 161 162 163 164

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Notes

Maintenance manual Ottawa 4x2, 6x4

Foreword

1

mm mm mm mm mm mm

Foreword page –

This service manual covers the Ottawa 4x2 and 6x4 terminal (yard) tractors produced by Kalmar Industries Corporation. You will find here descriptions of the features, location and operation of the components. Diagnostic and repair procedures are included along with schematic diagrams of the electric, pneumatic and hydraulic circuits. There is a table of specifications and a schedule for preventive maintenance. Basic information, diagnostic and repair procedures are provided for the uniquely Ottawa features and components. Designed to provide the owners and operators of Ottawa 4x2 and 6x4 terminal tractors with the information necessary to service and maintain their vehicles properly, this manual presents the information in eight sections. For the major components, such as engine, transmission and axles, follow the service instructions and guidelines provided by the component manufacturer. This applies also to lesser components, such as the steering gear, ABS controllers and other system components, that are produced by quality manufacturers and supplied to Kalmar for production of Ottawa vehicles. It is our hope that this manual will help you to realize maximum utility, efficiency, reliability and durability from your Ottawa tractor.


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Notes


1.1 The Ottawa Terminal Tractor – 1 Introduction

mm mm mm mm mm mm

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1 Introduction 1.1

The Ottawa Terminal Tractor

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Description The Ottawa terminal tractor by Kalmar is designed to suit the operator and the tasks. Ottawa tractors are purpose-built vehicles, designed to move trailers in the most efficient manner. Controls are conveniently arranged around the operator's seat. The operator can get into the cab from the side or through the sliding rear door. The sliding feature and latching in open and closed position means that the rear door is never in the way. Full-length grab-handles, large windows and easy access to all operator controls are some of the features of the efficiently designed cab. The trailer air lines and electrical connections are easily accessible through the rear door. Perforated decking allows the operator to move from cab to trailer comfortably and easily. A hydraulically powered boom under the fifth wheel raises a trailer high enough to allow it to be moved without raising and lowering its landing gear. These features along with in-cab fifth-wheel release and automatic relatch means that the operator is not required to climb up and down from the cab for every trailer move. The Ottawa also features automatic transmissions, hydraulic cab tilt for easy maintenance access, a short turning radius and matched drive train components with durable axles that simplify maintenance even further. Ottawa tractors are engineered for longevity and easy operation.


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1.2 Safety Summary – 1 Introduction

1.2

Safety Summary

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Hazardous Conditions The following signs accompanied by an explanation are used to advise the reader of the degree of hazard associated with the procedure being described.

D ANGER A situation that may result in serious personal injury, possibly death, if the instruction is not followed.

WARN IN G A situation that may result in serious personal injury if the instruction is not followed.

C AUTION A situation that may result in damage to the product if the instruction is not followed.

NOTE Information that is important without being safety related. Note is used to facilitate the work process, operation/handling or to increase understanding of the information. Do’s and Don’ts

WARN IN G Always disconnect the batteries before welding on or near the vehicle. Improper welding procedures may damage the alternator or batteries. Failure to heed this warning may result in serious personal injury or property damage.


1.2 Safety Summary – 1 Introduction

5

•

Do use care when removing the radiator filler cap. When the engine is hot, rotate the cap to the first detent, allow the pressure to dissipate and then remove it.

•

Do stay clear when lowering the cab.

•

Do set the parking brake when parking the vehicle.

•

Don't apply full throttle while the engine is cold.

•

Don't allow sparks or flames near a charging battery.

•

Don’t allow sparks or flames nearby when inspecting fuel, fuel tank or filler-neck strainer.

•

Don’t operate a vehicle in an enclosed area without adequate ventilation.

•

Don’t operate the vehicle with inspection plates, cover plate or engine access doors removed or open.

•

Don’t weld or flame cut frame rails or drill holes in rail flanges.

•

Don’t modify the vehicle or its equipment without the advice and written consent of the Engineering department at Kalmar.

•

Don’t push start the vehicle.

•

Don’t stand or work under a raised cab unless the safety prop on the tilt cylinder is locked.

•

Don’t jump start the vehicle using welding equipment.

•

Don’t operate the vehicle with air pressure below 70 PSI.

•

Don’t shift the transmission from neutral to drive or reverse at engine speeds above idle.


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1.3 Diesel Fuel Requirements – 1 Introduction

1.3

Diesel Fuel Requirements

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Precautions

WARN IN G Do NOT smoke when handling diesel fuel. Failure to heed this warning may result in serious personal injury and property damage. Use only the fuel specified by the engine manufacturer. Improper fuel can result in corrosion, damaging deposits and premature wear.

C AUTION Do NOT add anything but diesel fuel to the fuel tank. Drain the entire fuel system and fill with the correct fuel. Failure to heed this caution may result in serious property damage.

Avoid using smoke suppressant additives to prevent excessive ash deposits that may result in frozen rings and guttered valves. Refer to the engine manufacturer’s service manual for fuel requirements.


1.4 Emergency Starting – 1 Introduction

1.4

7

Emergency Starting

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Precautions When jump starting one vehicle from another, both electrical systems must have the same voltage rating and polarity.

C AUTION Verify that the polarity and voltage rating of the service batteries match the polarity and voltage rating of your Ottawa tractor before attempting to jump start a vehicle.

Due to the higher torque requirements for starting diesel engines, Ottawa tractors use multiple batteries. At low temperatures, it may not be possible to start the engine in an Ottawa tractor using only one battery.

C AUTION Never tow a vehicle in an attempt to start the engine. This may cause serious damage to the automatic transmission.

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Jump Starting Instructions 1. Position the vehicles so that the jumper cables reach comfortably but the vehicles do NOT touch. Ensure that the jumper cable insulation is NOT missing or loose. 2. Shift the automatic transmission to neutral and apply the parking brake. 3. Turn off the ignition switch and all lights and accessories in both vehicles. 4. Make sure the cable clamps do not touch other metal parts. Clamp one end of the first jumper cable to the positive terminal on one battery and the other end to the positive terminal on the other battery. NEVER connect positive to negative. 5. Clamp one end of the second cable to the negative terminal of the charged battery and the other end to the negative terminal of the dead battery. 6. Start and run the engine of the vehicle with the charged battery at moderate speed for several minutes, then start the engine in the vehicle that has the discharged battery.


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1.4 Emergency Starting – 1 Introduction

7. Remove the jumper cables by reversing the above installation sequence exactly. While removing each clamp be sure that it does not touch any other metal while connected to the other battery.

WARN IN G Batteries produce explosive gases, contain corrosive acid and generate levels of electrical current high enough to cause burns. To reduce the risk of personal injury when working near a battery: •

WEAR SAFETY GLASSES and avoid leaning over a battery whenever possible.

•

Do NOT expose a battery to open flames or sparks.

•

Ensure that batteries with fill caps are properly filled with fluid.

•

Do NOT allow battery acid to contact eyes or skin. Flush any contacted area thoroughly with water immediately and seek medical attention.

Failure to heed this warning may result in serious personal injury and property damage.


1.5 Vehicle Towing – 1 Introduction

1.5

9

Vehicle Towing

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Precautions Use proper equipment to prevent damage to vehicles during towing. Conform to applicable state and local laws for towing vehicles. Vehicles should not be towed at speeds in excess of 55 MPH. Connect towing equipment to main structural parts of the vehicle.

C AUTION Do NOT connect towing equipment to the bumper. Use tow hooks or tow eyes built into the frame. Use only towing equipment designed for the purpose. Follow the instructions of the wrecker manufacturer. Use safety chains. Failure to heed this caution may result in serious property damage. Secure all loose and protruding parts of the vehicles prior to towing. Do NOT stand or work under an elevated vehicle without adequate safety stands. Do NOT attempt towing operations that will jeopardize the safety of other motorists, bystanders or the towing or towed vehicles.

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Front End Towing (Front Wheels Off the Ground) To relocate a disabled vehicle by front end towing with front wheels raised off the ground, follow these steps. 1. Block the rear wheels of the disabled vehicle. 2. Release the parking brake as outlined in the brake section of this manual. 3. Disconnect the propeller shaft at the axle. 4. Secure the propeller shaft to the frame or cross member. 5. Remove the axle shafts if there is damage or suspected damage to the axle(s). 6. Cover the hub openings to prevent loss of lubricant or entry of dirt or foreign objects.


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1.6 Vehicle Modifications – 1 Introduction

When the vehicle has arrived at its destination, ensure it is safely positioned. 1. Block the rear wheels. 2. Install the axle shafts. 3. Remove the covers from the hub openings. 4. Align the universal joints and connect the propeller shaft. 5. Apply the parking brake before disconnecting the towing vehicle. 6. Check and fill rear axles with oil as needed. –

Front End Towing (All Wheels On the Ground) The vehicle may be towed with all wheels on the ground provided the steering system is operating normally. Remember that the steering will not have power assist and the vehicle will not have brakes. A tow bar must be used between the towing and the disabled vehicle. To relocate a disabled vehicle by towing with all wheels on the ground, follow the procedure described above for towing with front wheels off the ground. –

Rear End Towing When towing the vehicle with rear wheels raised, secure the steering wheel to maintain straight ahead position. Ensure that the front axle load is not more than the gross axle weight rating as indicated on the vehicle identification plate.

1.6

Vehicle Modifications

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Do not modify your Ottawa tractor without approval in writing from Kalmar Industries Corporation. Unauthorized modifications may void the vehicle warranty.


2.1 Location/Description – 2 Vehicle Identification

11

2 Vehicle Identification

mm mm mm mm mm mm

2.1

Location/Description

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OTT0010

Identification Plate A vehicle may be specifically identified by referring to the vehicle identification plate. The plate is located inside the cab on the top of the driver’s door frame at the rear. This plate shows the model, serial number and manufactured date for this vehicle.

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Certification Label

OTT0009

The certification label is supplied only for vehicles qualified under EPA/DOT regulations. It is located inside the cab on the post behind the driver’s door. The certification label shows the vehicle type and date of manufacture. Also shown are the Vehicle Identification Number (VIN), gross vehicle weight rating (GVWR), front and rear gross axle weight ratings (GAWR), wheel base, tire and rim sizes, and tire air pressure.

Serial Number

page –

OTT0011

The serial number is located on top of the left frame rail inboard of the cab air spring (above the rear spring hanger) and also on the identification plate (see above). Always refer to this number when ordering parts or requesting field service assistance.

page –

Engine Serial Number Cummins serial numbers are located on the left-hand side timing gear cover. Caterpillar serial numbers are located on the rear of the engine on the left-hand side. Maintenance manual Ottawa 4x2, 6x4

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Notes


3.1 Cab/Deck – 3 Description and Operation

13

mm mm mm mm mm mm

3 Description and Operation page –

The Ottawa 4x2 and 6x4 models are utilitarian vehicles with features designed specifically for application as yard tractors. Information describing the major components and systems of these vehicles is presented in this section under the headings of Cab/Deck and Chassis. When appropriate, the function and operation of the parts and systems is included.

3.1 3.1.1

Cab/Deck Construction

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Cab — The cab four walls, roof and deck are constructed of 12-gauge galvanneald steel for strength and rust protection. The walls are attached to the deck at four points by grade 5 bolts tightened to 120 ft. lb. The deck provides the floor inside the cab and the walkway outside the cab. The floor and walkway are covered by matting with an abrasive surface for safer footing. The instrument panel frame and the engine bulkhead inside the cab help make the assembly rigid. Insulation panels line the roof and the engine side of the bulkhead.

Ottawa 4x2 — Rear View with Tilted Cab

Roof — The roof of the standard cab rises at an angle from the windshield permitting a rear door opening approximately 68 inches high. Doors — The rectangular driver's door is attached to the cab by a full-length piano-type hinge. The rear door slides and latches in open or closed position and gives quick access to the walkway and frame decking. The orientation of the door in its opening is adjustable. Refer to the repair procedures section for more information. Windows and Ventilation — The window in the driver’s door moves up and down via a regulator handle on the door. A fixed side window ahead of the driver’s door permits a full view on that side. A small ventilator door below this window provides fresh air inside at the driver’s feet. A three-section window on the opposite wall allows an unobstructed view in that direction. The front and rear sections of this window slide horizontally as needed for ventilation.


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Access — A two-step ladder is attached to the cab deck by the side door. In addition, three steps made from 10-gauge perforated steel are mounted on the battery box for access to the frame decking and the rear door. Grab handles designed to accommodate entry to either door are attached to the rear cab wall. Perforated decking made from 10-gauge steel is attached across the frame rails at the rear of the cab. Additional perforated decking extends toward the fifth wheel on top of the boom.

Cab Access Ladders and Decking

3.1.2

Cab Mounting and Suspension

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Three-point suspension means that the cab is attached at two points in front by a pivot on each rail and latches to an air suspension system on one rail at a rear corner. The system consists of a latching catch bracket, two shock absorbers, an air cushion and an adjustable height control valve. Air is supplied via the vehicle air system. Correctly adjusted, the system controls the ride height and relieves stress on the cab pivots. A cab leveling valve works automatically when a load is applied (e.g., when someone steps into the cab or pulls down strongly on a cab entry handle). The flow of system air for adjustment is audible. The sound can be used to determine the serviceability of the valve. Adjustment should be complete in two to 10 seconds.

Cab Air Suspension and Latching System



3.1.3

15

Cab Tilting

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The cab can be tilted to 45° by means of the hydraulic system. The cab can be tilted to 90°, if needed, by providing a suitable hoist to carry the weight and disconnecting the lift cylinder. A hydraulic cylinder mounted between the deck and the frame at a front corner raises and lowers the cab. The hydraulic pump is actuated by a well-marked switch on the outside of the rail near the rear axle. Also provided is a lanyard by which to unlock the cab safety prop during the raising or lowering operation.

Cab Tilt Cylinder and Safety Prop The cab attaches and pivots in front on two pins. The pins are fastened to the front ends of the rails.

Left Front Cab Tilt Pivot


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The hydraulic system electric pump motor is mounted on the transmission housing. It serves all hydraulic circuits on the tractor.

Electric Pump Motor — Hydraulic System The cab tilt control switch and lanyard are located on the rail between the hydraulic fluid tank and the rear wheel. Tilt action stops when the switch is released or when the cab reaches full up or full down position.

Cab Tilt Control Switch and Lanyard After the cab reaches the full down position, the latching mechanism makes a loud sound. The latching bar alignment can be adjusted. Refer to the repair procedures section for more information.

Cab Suspension Latching Bar



3.1.4

17

Seating

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The tractor is fitted with a seat suspended on an air spring. The firmness of the ride is adjusted by changing the air pressure. Seat height adjusts by changing the air pressure. A switch on the side of the seat controls the air pressure. Seat height is fixed by adjusting the tethers attached to each seat belt anchor. The seat position can be adjusted fore and aft. The position of the seat cushion can be adjusted fore and aft independently of the seat position. A fore and aft isolator is included for snubbing undesirable chugging. This locking lever is mounted on the inside of the seat.

Driver's Seat — Side View

3.1.5

Instrument Panel Gauges, Controls and Indicators

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Gauges, controls and indicators appear in five panels in front and to the side of the driver as shown below. Panels 1 and 2 mount in front of the steering wheel. Panel 3 is mounted in the transition between the cab instrument panel and the top of the bulkhead assembly. Panels 4 and 5 are mounted on top of the bulkhead assembly. Panels 1 and 2 are backlit when the headlights are on. The dimmer switch is optional.

Instrument Panel Surround Panel 1 — displays the following gauges, controls and indicator lights along with an air diffuser for the heating and optional air conditioning system. •

Gauges and Controls – Fuel – Oil Pressure – Water Temperature – Tachometer (Optional) – Speedometer (Optional) – Headlight Switch – Panel Dimmer Switch (Optional)

Instrument Panel 1


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•

Indicator Lights – Wait to Start – Service Soon – Check Engine – Stop Engine – Left Turn

Panel 2 — displays the following gauges, controls and indicator lights. •

Gauges and Controls – Hourmeter – Voltmeter – HVAC Temperature Control – HVAC Directional Controls – Fan Speed Switch (HVAC) – AC On/Off Switch (Optional) – Flood Light Switch

Instrument Panel 2

– Ignition Key Switch – Windshield Wiper Switch (Optional) – Windshield Washer Switch (Optional) •

Indicator Lights – High Beam – Right Turn – Low Brake Air Pressure (lit below 70 PSI)

Panel 3 — may be blank, but it is available for additional gauges, controls and indicators as needed. Panels 4 and 5 — display the following gauges and controls.

Instrument Panels 4 and 5

•

Air Gauge

•

Second Air Gauge (with split air system)

•

Tractor Park Control

•

Trailer Air Supply Control

•

Transmission Shifter

•

Fifth-Wheel and Boom Control

•

Fifth-Wheel Latch Control

Electroluminescent (EL) displays for the transmission shifter and the fifth-wheel control glow when the ignition switch is in the On position. Each of the panels has room to add additional gauges and indicator lights as needed.



3.1.6

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Electrical Equipment

The wiring harness can accommodate several items of optional equipment. Contact your dealer for information about any equipment installed after the vehicle left the factory.

page –

Lighting — Kalmar provides a dome light, instrument panel lighting, headlights, marker lights and a trailer electrical connector with circuit breakers. A work area floodlight and a beacon are mounted on an upper rear corner of the cab. An optional strobe light may be substituted for the beacon.

Trailer Electrical Connector and Brake Hoses

Fuses, Relays and Circuit Breakers — The fuse panel is mounted underneath the instrument panel on the right side. The relay panel is mounted under instrument panel 1. The fuse panel cover includes diagrams of the panels.

3.1.7 page –

Heating/Air Conditioning

A heater is standard equipment. Air conditioning is optional. Air diffusion is provided through ducts in the instrument panel near the side window and underneath the instrument panel near the center of the cab. Air flow can also be directed to the windshield and side windows. Instrument panel controls give the driver several air handling options including fan speed and cab air temperature.

3.1.8 page –

Accessories and Options

Mirrors — Heated and heated/motorized outside rear view mirrors are optional equipment. Radio — A radio is an available option. Windshield Wiper — Also optional equipment, the wiper is electrically driven. A rotary switch on the instrument panel also controls its operating speed. The Off parked position is at the counterclockwise limit. Maximum speed is at the clockwise limit. Windshield Washer — A windshield washer system is also an available option.


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3.2 Chassis – 3 Description and Operation

3.2

Chassis

3.2.1

Frame

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11

12

10

6

7

8

9

5 4 3 2 13 1 14 15

16 17 20

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OTT0070

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19 Frame Construction 1. Main Rail (2)

12. Weldment, Cross Member and Ramps

2. Inverted-L Channel Rail Reinforcement (2)

13. Axle Mounting Bracket (4)

3. Triangular Brace (2)

14. Boom Lift Cylinder Mounting Weldment (2)

4. Inverted-L Channel Welded Riser (2)

15. Boom Lift Cylinder Pivot Bushing

5. Inverted-L Channel Welded Support (2)

16. Front Spring Rear Mounting Bracket (2)

6. Inverted-L Channel Median Cross Member

17. Rear Motor Mount (2)

7. Fifth-Wheel Boom Pivot Bushing (2)

18. Front Motor Mount (2)

8. L Channel Support (2) 9. L Channel Support (2)

19. Front Spring Front Mounting Bracket with Tow Hook (2)

10. Inverted-L Channel Welded Reinforcement (2)

20. Front Cross Member

11. Rail Reinforcing Plate (2)

21. Cab Pivot Pin Bushing (2)



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The frame rails are reinforced C channels. Flat plates are welded to the upper and lower flanges of each rail near the outer edges forming boxes. These plates reach from the cross member at the rear end of the cab to a point under the ramp at the rear ends of the rails. The cross member is bolted to triangular braces welded to the forward ends of these plates. The triangular braces are also welded to the upper flanges of the rails. Inverted L-shaped reinforcements are welded to the outside of the C channel stretching from the cross member to the rear axle. Other short inverted L-shaped pieces are welded to the tops of the flanges near the fifth wheel. Short, upright L-shaped reinforcements support the lower flanges of the rails at strategic points. There is one cross member located near the rear of the cab. In front, the rails are held square by the weldment that anchors the cab pivot pins and in the rear by the weldments that form the ramp. A weldment structure extends downward from each rail ahead of the rear axle to provide anchor points for the lower ends of the boom cylinders. The front end of the boom rides in pivot points through the rails. Additional reinforcements are welded to the rails in locations designed to provide extra support for the frame under high torsional or shock loads.


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3.2.2

Powertrain

page –

Engines — The Ottawa yard tractor is designed to utilize the benefits of a six-cylinder diesel engine of the type customarily found in fire engines, dump trucks and refuse haulers. Engine options are provided for OFF-HIGHWAY and DOT/EPA certified applications with a choice of power ratings available from several engine manufacturers. Transmission — The standard transmission is an automatic Allison, RDS series. Axles — An Ottawa tractor will be equipped with one of several manufacturer’s rear axles. Special features, such as a locking or a “No-Spin” differential, are optional. Contact your Kalmar dealer if you do not know whether your vehicle contains these features. Service and Maintenance Information — For service and maintenance information, consult the manuals included with your vehicle, contact the Kalmar dealer or the manufacturer of the component installed in your vehicle.

3.2.3

Vehicle Suspension Including Otto-Ride

page –

The front suspension consists of shackled leaf springs. There are 10 steel leaves on the driver’s side and nine on the other side. Rubber blocks mounted on each axle reduce the shock of bottoming out.

OTT0027

RUBBER BLOCK

Leaf Spring Suspension

OTT0028

The front spring anchors and tow hooks are parts of special components welded to the front ends of the rails. Another weldment provides attachment for the rear spring hanger on each side.

Front Spring Anchor and Tow Hook



23

OTT0029

Eyes at the rear of the front springs connect to the rear spring anchor via shackles and pins. Bushings on each pin help to reduce friction.

Rear Spring Hanger The standard vehicle is equipped with a rear axle (or axles) attached directly to the frame rails without any suspension system. Axle housings are rigidly attached to the frame, captured by means of weldments mounted inside and outside of each rail. Otto-Ride — Optionally, a system can be installed to soften the ride at the rear axle. This suspension frees the axle housing from rigid attachment to the frame rails. The boom lift cylinders are attached to the forward side of the axle housing instead of the rails. To resist axle housing rollover and limit misalignment, a special frame is attached between the rails above and behind the axle housing. A hollow cylindrical rubber cushion mounted on this special frame limits the axle housing rollover. Sideways motion is limited by a torque rod attached to the special frame and the right side rail. Rear Axle Attachment


24


3.2.4

Air System and Brakes

page –

The main function of the vehicle air system is to provide compressed air to operate the brakes. Compressed air also operates the cab suspension, driver’s seat suspension and posture features, fifth-wheel unlatching, trailer brakes and optional interaxle lockout. page –

Brake System Major components of the air brake system include the following items. •

Air Compressor and Governor

•

Foot Pedal (Treadle Valve)

•

Air Control Valves

•

Air Reservoirs (Air Storage)

•

Air Dryer (Optional)

•

Tractor Protection Valves

•

Proportioning (Bobtail) Valve (Optional)

•

Quick Release Valves

•

Double (Two-Way) Check Valves

•

Brake Chambers and Parking Brakes

•

Slack Adjusters

•

Foundation (Wheel) Brakes

•

Trailer Brake Air Lines

•

Stop Light Switch

Within the system are two separate air distribution circuits. These operate the rear (primary) and front (secondary) foundation brakes. Air flow within the two circuits is controlled through a series of valves which supply or release air to the chambers in response to the driver’s command. The parking brakes are spring-actuated, but compressed air is required to release them. A buzzer and an indicator light warn of low pressure in the system when pressure falls below 70 PSI. The air pressure gauge reflects the actual system pressure.



25

Air Compressor and Governor — Pressure is supplied by a reciprocating piston-type compressor mounted on the engine. The compressor shares engine lubrication and coolant systems. Running continuously, the compressor requires a governor to maintain the necessary system pressure. The governor is mounted on the compressor. Operating in conjunction with an unloading valve, the governor directs air into the reservoirs or out the exhaust port. Foot Pedal (Treadle Valve) — This foot-actuated valve is actually two valves that operate in quick sequence. It is connected in the front and rear brake circuitry so that the rear brakes begin to act before the front brakes when the operator steps on the pedal. When air pressure is correct in both circuits, the second stage is driven via air pressure by the first stage. If air is lost to the first stage, the second stage is driven mechanically by the first stage.

Air Compressor Governor

Air Control Valves — There are two air control valves on the instrument panel. The tractor parking brake has a yellow knob. The trailer air supply knob is red. Normal vehicle operation with trailer in tow requires that both knobs be depressed. All braking control then transfers to the foot pedal. Operating in bobtail mode requires that the red knob be pulled out (stop trailer air supply) and the yellow knob be depressed (release tractor parking brakes). Air Reservoirs — The air reservoirs maintain a sufficient quantity of air under pressure to sustain several applications of the brakes. On vehicles equipped with the anti-lock brake system, there are three reservoirs. Other vehicles have only two. In the three-reservoir system, one serves as the primary, sometimes called the wet tank. It supplies air to the other two reservoirs independently. A pressure relief valve in the primary tank protects the system from excessive pressure.

Instrument Panel 4 — Trailer Air Supply and Tractor Parking Control Knobs

One of the two secondary reservoirs supplies air to the front brakes and the other to the rear brakes. Check valves prevent air from returning to the compressor when it is not running. This arrangement allows one set of brakes to operate in the event the other should fail.


26


In the two-reservoir system, compressed air goes to the supply tank where it passes through to the service tank and from there to the rest of the system. A pressure relief valve in the supply tank protects the system from excessive pressure. Each tank has its own drain valve to release water and oil that may have accumulated in the tank during operation.

SUPPLY TANK

System pressure is monitored by a low pressure sensor that communicates with an indicator light mounted in the instrument panel and a buzzer mounted on an electrical relay panel on the cross member below the steering column. The indicator and buzzer are activated while the system pressure is below 70 PSI.

FRONT

OTT0013

SERVICE TANK

Air Storage Tanks — Two-Reservoir System

Air Dryer — An air dryer for the brake system is available as optional equipment. In the circuit between the compressor and the reservoir, it removes water vapor from the air. It also removes any oil vapor that may blow by the compressor. Tractor Protection Valves — Located in the circuitry between the tractor and the trailer, a special valve responds to the trailer air supply knob, or to a broken trailer air line, by cutting off the air supply to the trailer system. Proportioning Relay (Bobtail) Valve (Optional) — Available as an option, this valve is designed to detect if a trailer is connected to the brake air system. When a trailer is not present, the valve causes the front brakes to do a larger percentage of the work than when a trailer is present. Connected downstream of the primary reservoir, system air enters its supply port. If no trailer is present, pistons in the valve are repositioned so that, when the pedal is applied, a larger percentage of air goes to the front brakes causing them to assume a greater part of the work of stopping the tractor. If a trailer is present and the trailer supply valve is opened, a portion of the trailer supply air enters the proportioning valve through its control port. The valve restores its internal pistons to their original positions. Air passes normally through the valve to the rear and trailer brakes. Anti-Compounding Valve (Optional) — Also available is an anti-compounding valve that prevents the service brakes from adding to (compounding) the effort exerted by the parking brakes. It protects against brake cracking and damage to the linings. Quick Release Valves — Each brake chamber connects to its own quick release valve nearby. This valve responds to the release of the foot pedal. The purpose of this valve is to dump the air out of the spring chambers much more quickly than would be possible if the air had to travel back through the supply lines.



27

Double (Two-Way) Check Valves — These are used to sense pressure from front and rear, or supply and service, and allow the dominant pressure to actuate the trailer brakes, the stop light switch and release the parking brakes. A two-way quick release valve combines the two functions in a single housing. Brake Chambers and Parking Brakes — In the front are two single chamber units at the wheel ends. These operate the foundation brakes described below. In the rear are two dual chamber units at the wheel ends. These operate both the foundation brakes and the parking brakes. When there are dual rear axles, brake chambers are typically mounted on the forward axle, but are sometimes supplied on both axles. The brake chamber is designed to move the shoes against the drums using air pressure. Air pressure is released into the chamber by the foot pedal. Push rods change the air pressure into mechanical action to rotate the brake cam shafts. The push rods in the brake chambers provide a 2.25–2.50-inch range of stroke length. The second chamber in the dual chamber unit uses the air pressure to keep a powerful spring compressed. This spring, attached to the push rod, provides the parking brake action. When system air pressure falls below 43 PSI, the springs activate the push rods and apply the foundation brakes. When system air pressure rises above the set point, it overcomes the spring pressure and releases the brakes. For service, the springs can be released manually if the engine cannot be started, or if air pressure cannot be restored to the system.

BRAKE CHAMBER PUSH ROD

S-CAM BRAKE SHOES BRAKE DRUM Slack Adjuster Diagram

OTT0012

SLACK ADJUSTER

Slack Adjusters — Slack adjusters change the distance the brake shoes have to travel to contact the drum. During each application of the brakes, automatic adjusters detect the rotation of the brake cam shaft. They retain the setting at the point where the lining contacts the drum. This setting changes as the drum and linings wear. Manual adjusters include a worm gear and an adjusting screw that provide the means to reset the clearance between the shoe and the drum. Manual adjustments have to be made when the vehicle is stationary and the adjusting screws are accessible. Foundation (Wheel) Brakes — The foundation brakes consist of brake drums on the wheels and shoes lined with friction material attached to the axles. Actuated via cams rotated by push rods in the brake chambers, the shoes are pressed against the drums. Air pressure controlled by the foot pedal supplies the force necessary to stop the wheels from rotating.


28


Trailer Brake Air Lines — Coiled service (blue) and supply (red) lines provide trailer braking controls. Both air lines must be connected in order to release the trailer parking brakes. Stop Light Switch — This is an air-actuated switch that causes the stop lights to illuminate when system air pressure increases to 5 PSI after depressing the foot pedal.

Trailer Electrical Connector and Brake Hoses page –

Anti-lock Brake System (Optional) Some vehicles will be equipped with an anti-lock brake system (ABS). This system prevents the wheels from completely stopping rotation (locking up) when the brakes are applied. The benefit of this is to overcome the tendency of a vehicle to lose steering control during emergency braking. Toothed rings and sensors at the wheel ends work together to reflect individual wheel speeds. The sensors send the data to the EC-60 electronic control unit mounted in the left front wheel well. The anti-lock modulator valve in conjunction with the EC-60 electronic control unit responds to the signals from the sensors to control the air pressure at the individual wheel brakes. As a wheel’s speed approaches 0 rpm (locked up), air pressure to that brake is repeatedly released and reapplied. The process continues until all wheel speeds are equal. Braking action then continues evenly until the foot pedal is released. There is an indicator light on the instrument panel to warn when the system malfunctions. This system can also check the trailer for a proper operating system. A malfunction in the trailer system actuates a separate light on the instrument panel. Diagnosis and fault code clearing are available through the EC-60 electronic control unit if so equipped. There is a diagnostic connection behind the grille opening in the front bumper. The connection can be used by a laptop with appropriate software or a handheld Bendix RDU diagnostic tool. page –



29

Automatic Traction Control (Optional) Some vehicles that are equipped with ABS may also be equipped with full-time automatic traction control (ATC). The ATC indicator lamp blinks when ATC is working. ATC uses the ABS wheel sensors. It compares front wheel speed to rear wheel speed and left rear wheel speed to right rear wheel speed. When a set ratio is exceeded, ATC applies the rear brakes to the appropriate wheel end. ATC operates only at speeds less than 25–30 miles per hour. At higher speeds, vehicle reaction to a sudden application of the brakes on one side may cause loss of driver control.

3.2.5

Hydraulic System

page –

System Overview The hydraulic system of the current production Ottawa tractors is composed of three subsystems. They are the boom (hoist), cab tilt and power steering. The common link among these three subsystems is the shared reservoir, return filter and hydraulic fluid. With the exception of these items, all subsystems operate independently. The three subsystems have their own control valves and output actuators (cylinders). The power steering is an open-centered circuit; that is, hydraulic oil flows continuously through the center of the control valve even while the steering wheel is not moving. Power steering and the boom systems use the same hydraulic pump. The pump is equipped with a priority valve that directs the first four gallons per minute of flow to the steering circuit. Reservoir, Fluid and Filter — The standard hydraulic reservoir has a 16-gallon capacity. It is fitted with a level sight gauge and a breather. The return filter is located near the tank in the boom circuit return line, where it is continuously filtering fluid that is used in all three subsystems: boom, cab tilt and power steering. page –


30


Boom Components 1. Boom Pivot

5

2. Boom

4 *

3. Boom Lift Cylinder Pivots

3 *

4. Fifth-Wheel Pivot

2

* BOTH SIDES Elevated Boom with Fifth Wheel

OTT0002a

1 *

5. Fifth-Wheel Plate The standard hydraulically operated boom is the basis for the fifth-wheel lifting system. The forward end of the boom assembly is attached to the frame at a pivot point behind the cab. Mounted at the rear of the boom is the fifth wheel which is raised and lowered through the action of two hydraulic cylinders installed between the boom and frame weldments just forward of the rear axle. Power to operate the cylinders is supplied by the hydraulic pump mounted on the transmission. Boom Lift Cylinders — The standard configuration utilizes two 5-inch diameter lift cylinders with a capacity of 60,000 pounds and a lifting height of 17 inches. The cylinders are double acting in that they are hydraulically powered up and down. Restrictor fittings are threaded into the base end work ports to better control downward (lowering) speed. Hydraulic Pump — On a standard chassis, the hydraulic pump is a fixed, positive displacement gear type. The pump is rated at 10 gallons per minute at high idle (approximately 1200 RPM). A relief valve in the lift control valve limits operating pressure. Control Valve — The valve housing is a one-piece mono-block casting. The “A” and “B” work ports are precision machined and threaded to accept the “T” and “P” pressure (inlet) passages. The valve is open-centered and closed port. Incorporated in the valve assembly are load check valves and a relief cartridge with a maximum relief pressure of 2000 PSI for the 5-inch diameter cylinders. The valve is actuated remotely from the cab by the boom lift control lever. The boom lift control lever is attached to a control cable that pulls and pushes the control valve spool to the desired positions.



page –

31

Cab Tilt Components The cab tilt system is an electro/hydraulic system that utilizes the tractor battery to power an electric motor that drives the hydraulic pump. The inlet port of the pump draws in hydraulic oil from the common reservoir. This fixed displacement pump forces the oil through its outlet port, through the valve pressure passage, out the work port, and to the base end of the tilt cylinder. Because of the load, pressure rises until the piston moves the rod, thereby raising the cab. If the switch is held in the Up position after the cylinder has fully extended, pressure will rise to the relief setting of 3200 PSI. The relief valve will open and pressure will not increase above the set point.

Cab Tilt Cylinder and Safety Prop When tilting the cab back down, the solenoid-operated directional control valve (with two positions) is energized. The valve shifts position and allows a return path for oil from the tilt cylinder. A one-way check valve blocks oil returning from the relief valve and pump inlet and directs it through a return filter and through the valve passage. It goes through a restriction, which is pressure compensated, and then back to the pump inlet and on to the reservoir.

Electric Pump Motor — Cab Tilt

When the solenoid-operated control valve is de-energized, a simple spring load returns it to the blocked position. The function of the return restriction is to slow the rate of oil exhausting from the tilt cylinder. The effect of this restriction is to provide a slow, controlled return to the Down position for the cab. Cab Latch — One hydraulic cylinder and one mechanical locking mechanism are utilized to safely secure the cab in the Down position. The locking fingers are spring-loaded to the Lock position and are unlatched by the cylinder during the tilt up operation. The latching cylinder simply tees into the work line that connects to the base end of the tilt cylinder.


32


The latch cylinder and the tilt cylinder receive hydraulic oil under pressure at the same time. Since the latch cylinders require less pressure to operate, they will unlatch prior to the lifting of the cab. After they are unlatched and pressure rises, the tilt cylinder will extend, raising the cab. Cab Tilt Safety Prop — An additional mechanical safety device is used to ensure that the cab cannot be inadvertently lowered. The cab safety prop is similar to a hood prop in function; but instead of holding the hood (or cab in this case), it acts as a solid arm locking the hydraulic tilt cylinder in the extended (cab-tilted) position. It is cable-operated from the tilt operation station where the control switch is located.

Cab Tilt Control Switch and Lanyard page –

Power Steering Components The standard power steering system uses an integral power steering gear and the transmission-mounted hydraulic pump. The system operates on fluid drawn from the common reservoir shared with the boom and cab tilt systems. Integral Power Steering Gear — When the steering wheel is turned, force is transmitted from the steering wheel to the steering gear input shaft. A torsion bar pinned at one end to the input shaft and at the other end to the worm shaft, turns with the input shaft and exerts a rotational force on the worm shaft. In response to this rotational force, the worm shaft, acting through the recirculating ball mechanism, moves the rack piston axially through the gear-housing cylinder bore. The rack piston’s axial movement is resisted by its engagement to the sector shaft, which is connected by linkage to the steered wheels. Because of this resistance, the input shaft actuates the control valve and twists the torsion bar. Pressurized fluid directed by the control valve, assists in moving the rack piston axially through the cylinder bore. The rack piston then turns the sector shaft to steer the vehicle.



3.2.6

33

Fuel System

page –

Fuel Tank — Brackets bolted to the rail hold the 24-inch diameter, 50-gallon fuel tank. Two-inch wide straps secure the tank to the two mounting brackets. Rubber strap liners protect against chafing between the straps and the tank. The manufacturer’s name plate is fastened to the side of the tank where it can easily be seen. Fuel Level Sending Unit — The tank is fitted with a fuel level sending unit and a vent plug. A float riding on the surface of the fuel causes current changes which are transmitted via the sending unit to the instrument panel gauge. Fuel Hoses — Fuel hoses are constructed of rubber and braided steel wire. Fuel Tank and Fittings


34

Notes


4.1 Chassis/Cab, Left Side – 4 Component Location

35

4 Component Location

mm mm mm mm mm mm

4.1

Chassis/Cab, Left Side

page –

Ottawa Series, Left Side (4x2 chassis shown)

6 1

4

5

2

13 16

15

12

11

10

9

14


8

7

OTT0005

3

36

4.1 Chassis/Cab, Left Side – 4 Component Location

1. Cab Air Ride Air Spring 2. Height Control Valve Assembly 3. Side Entry Ladder 4. Cab Tilt Switch 5. Boom Lift Cylinder Upper Mount 6. Fifth-Wheel Pivot 7. Boom Lift Cylinder Lower Mount 8. Cab Tilt Lanyard 9. Hydraulic Fluid Tank 10. Hydraulic Fluid Filter 11. Battery Box — BOC Steps 12. Cab Tilt Pump 13. Fuel Filter 14. Cab Air Ride Shock Absorber 15. Cab Tilt Cylinder Safety Bar 16. Tow Hook


4.2 Chassis/Cab, Right Side – 4 Component Location

4.2

37

Chassis/Cab, Right Side

page –

Ottawa Series, Right Side (4x2 chassis shown)

3

4 1

8

7

6 1. Fifth-Wheel Pivot 2. Boom Lift Cylinder Upper Mount 3. Vertical Muffler and Exhaust Pipe 4. Engine Access Panel 5. Tow Hook 6. Hydraulic System Pump 7. Fuel Tank 8. Boom Lift Cylinder Lower Mount


5

OTT0006

2

38

4.3 Chassis/Cab, Front/Rear – 4 Component Location

4.3

Chassis/Cab, Front/Rear

page –

Ottawa Series, Front/Rear (4x2 chassis shown)

3

4

2 6

7

5 1. Front Panel (Removable) 2. Rear Door 3. Glad Hands (Air Brake) 4. Trailer Electrical Connector (7-pin) 5. Air Brake Chambers (Rear Axle) 6. Fifth-Wheel 7. Front Leaf Springs


OTT0007

1

4.4 Chassis, Plan View – 4 Component Location

4.4

39

Chassis, Plan View

page –

Ottawa Series, Plan View (4x2 chassis shown) 2

3

4

5

6

7

8

9

10

11

17

16

15

14

13

1. Fifth-Wheel Boom 2. Hydraulic Fluid Tank 3. Hydraulic Fluid Filter 4. Air Tank, Service (Air Brakes) 5. Battery Box — BOC Steps 6. Boom Pivot 7. Fuel Filter 8. Cab Lift Cylinder 9. Radiator/Charge Air Cooler 10. Cab Pivots 11. Optional Air Dryer 12. Engine Oil Dipstick 13. Air Cleaner 14. Transmission Fluid Dipstick 15. Air Tank, Supply (Air Brakes) 16. Fuel Tank 17. Fifth-Wheel


12

OTT0008

1

40

Notes

5.1 Safety – 5 Diagnostic Procedures

mm mm mm mm mm mm

41

5 Diagnostic Procedures 5.1

Safety

page –

Summary Safety always comes first. There are comprehensive reminders in the early pages of this manual of the precautions that are required while working around any vehicle. Information will be found there about towing these yard tractors. Welding is also covered as is safe battery handling.

5.2

Electrical

page –

Guide to Troubleshooting This guide is provided for diagnosis of problems in Ottawa Truck DATCON electrical instruments. The sequence presented is intended to minimize duplication. Follow the sequence as described to prevent misdiagnosis. This guide presumes that senders and gauges are properly matched and wired and that the correct voltage is applied.

WARN IN G Ensure that the gauges and senders are matched and properly wired in circuits with correct voltage. Failure to heed this warning could result in personal injury and property damage. page –

Basic Gauge Diagnostic Procedure Schematics and diagrams of the electrical circuitry appear in Section 9, Schematics. The following steps describe the general path to follow when troubleshooting electrical faults that show up on instrument panel gauges. 1. On replacement parts, check the part numbers of the gauge and sender to ensure they are matched, and match the voltage in the vehicle (12 VDC or 24 VDC). 2. Inspect the wiring between the gauge and sender. Wiring should be intact and tightly connected. Tighten and replace wiring as required. 3. If the gauge still does not work, ensure that the steel housing of the sender is properly seated. Provide a three-wire jumper to bypass the system wiring. Connect ignition (or accessory) voltage to the "I" terminal on the back of the gauge. Connect the system ground wire to the "G" terminal and the sender signal lead to the "S" terminal. Maintenance manual Ottawa 4x2, 6x4

42

5.2 Electrical – 5 Diagnostic Procedures

A. Without power, the gauge pointer may indicate any value. Often, it will indicate the previous signal from the sender. B. Turn on the ignition without starting the engine. The pointer should indicate zero or full PSI. If the pointer indicates outside the endpoints, go to step 3Bc below. If the pointer falls within the endpoints, go to step 3Bd below. a. If the pointer is stuck noticeably outside dial scale endpoints, lightly tap the lens. If tapping results in the pointer moving to an acceptable position, look for an open in the sender circuit or replace the gauge. Go to step 3Bc below. b. If the pointer rests significantly toward the far left of the scale, remove power to the gauge. Remove the sender wire from "S" terminal on the back of the gauge. Momentarily apply power to the gauge. If the pointer does not travel to the far right of the scale, replace the gauge. c.

If the pointer rests significantly toward the far right of the scale, remove power to the gauge. Remove the sender wire from "S" terminal on the back of the gauge. Test the resistance of the sender and its wiring using an ohmmeter. The reading should be between 0-250 ohms. If the resistance is more than 250 ohms, check the sender wiring to sender housing or flange grounding. Also, look for an open in the sender wiring circuit. If the electrical wiring is correct and properly grounded, remove the sender and test the sender resistance independent of the installation. If it is not within specifications, replace the sender.

d.

If the pointer is within the dial scale endpoints, disconnect the sender wire from the sender. Keep the sender installed in its proper location. Allow the sender wire to hang freely.

C AUTION The sender lead must be disconnected for this test. Failure to heed this caution will result in severe damage to the sender.

Momentarily apply power to the gauge. The pointer should move off scale to the extreme left. Remove power from the gauge.



43

e. Grounded Sender Test — Attach the sender wire from the gauge to an established chassis ground. Momentarily apply power. The pointer should move to the far right of the scale. Remove power. If the gauge fails this test, replace the gauge and retest. Go to step 3A above. 4. If the pointer jumps rapidly, overshoots or oscillates around the rest position, the sender connection contact is intermittent. Trace the sender wiring and verify that the gauge and sender connections are secure. If connections are tight and in good condition, replace the gauge. 5. If the pointer stops, hesitates or shows any evidence of sticking, replace the gauge. 6. If the pointer moves extremely slowly, replace the gauge. 7. Remove power and attach sender wire to "S" terminal on back of the gauge. Check operation with system sender. If the gauge does not operate correctly, troubleshoot sender circuit as in step 3Bd.

5.2.1

Engine

page –

Starting and Charging Components •

Alternator

•

Batteries

•

Ignition Switch

•

Starter

•

Starter Relay

•

Starter Solenoid

Starting and Charging Circuit Diagnosis Observation Battery charge low/discharged

Engine does not crank

Cause

Action

Defective wiring

Inspect connections and wires. Test circuits. Repair or replace as needed.

Defective battery

Replace as needed.

Defective alternator

Repair or replace as needed.

Battery charge low/discharged

See above.

Defective wiring


Defective relay

Replace.

Defective solenoid

Replace.

Defective starter

Replace.


44


5.2.2

Cab Instruments

page –

Low Air Warning The vehicle will be equipped with one of two air braking systems. Vehicles that travel on the roads are made to comply with the regulations in Federal Motor Vehicle Safety Standard (FMVSS) 121. Vehicles that do not travel on the roads have an equally reliable braking system. An anti-lock braking system option may also be found on the vehicle. Components •

Air Pressure Gauge

•

Headlight Switch

•

Low Air Buzzer

•

Low Air Pressure Switch (Indicator)

•

Low Air Warning Light

•

Panel Dimmer Switch (Optional)

Refer to Basic Gauge Diagnostic Procedure page 41. Low Air Warning Circuit Diagnosis Observation Inoperative light and buzzer

Inoperative buzzer, light OK

Inoperative light, buzzer OK

Cause

Action

Circuit breaker open

Reset. Replace as needed.

Short circuit

Test. Repair as needed.

Switch grounded


Defective air switch

Test. Repair as needed

Defective assembly

Replace.

Open circuit


Defective buzzer

Replace.

Open circuit


Bulb burned out

Replace.

–



45

Ammeter Components •

Ammeter

•

Headlight Switch

•


•

Shunt

Refer to Basic Gauge Diagnostic Procedure page 41. Ammeter Circuit Diagnosis Observation Zero reading

Cause

Action


Reset. Repair short as needed. Replace circuit breaker as needed.

Open circuit, loose connection


Defective gauge

Test. Replace as needed.



Inaccurate gauge

Defective gauge


Does not return to zero with ignition off

Defective gauge


–


46


Coolant, Oil and Fuel Gauges Coolant Gauge Components •

Cab Accessory Circuit Breaker

•

Coolant Temperature Gauge

•

Coolant Temperature Sending Unit

•

Headlight Switch

•

Ignition Switch

•


Oil Pressure Gauge Components •


•

Headlight Switch

•

Ignition Switch

•

Oil Pressure Gauge

•

Oil Pressure Sending Unit

•


Fuel Gauge Components •


•

Fuel Level Gauge

•

Fuel Level Sending Unit

•

Headlight Switch

•

Ignition Switch

•


Refer to Basic Gauge Diagnostic Procedure page 41. Coolant Temperature, Oil Pressure or Fuel Gauge Circuit Diagnosis Observation Zero reading

Cause

Action



Open circuit, loose connection


Defective gauge




Inaccurate gauge

Defective gauge


Does not return to zero with ignition off

Defective gauge


–



47

Hourmeter Components •

Cab Accessory Fuse

•

Hourmeter Gauge

•

Ignition Switch

•

Oil Pressure Switch

Refer to Basic Gauge Diagnostic Procedure page 41. Hourmeter Circuit Diagnosis Observation Inoperative

Intermittent

Runs unevenly, or fast or slow

Cause

Action



Defective wiring


Mislocated wiring

Inspect routing. Relocate wires or isolate terminals as needed.

Defective wiring

Inspect wires for kinks and breaks. Repair or replace as needed.

Mislocated wiring


Defective gauge

Replace.

–


48


Speedometer The speedometer may include an optional connection to the pulse generator. Components •


•

Electronic Speedometer

•

Headlight Switch

•

Ignition Switch

•


•

Pulse Generator (Optional)

Refer to Basic Gauge Diagnostic Procedure page 41. Electronic Speedometer Circuit Diagnosis Observation Panel lamp does not light

Inaccurate

No reading

Cause

Action



Loose lamp

Inspect lamp. Tighten or replace as needed.

Burned out lamp

Inspect. Replace lamp (match system voltage).

Defective wiring


Wrong DIP switch settings

Correct settings. Refer to the manual for specifications.

Change of tire size, gear ratio or pulse source

Calculate pulses per mile (kilometer). Recalibrate speedometer as described in the DATCON manual.

Defective wiring or sender

Inspect connections and wires. Test circuits. Inspect sender. Repair or replace as needed.



Mislocated wiring


Wrong DIP switch settings

Correct settings. Refer to the manual for specifications.

Defective wiring


Pulse generator gears damaged

Replace gears.

Pulse generator inoperative

Replace generator.



49

Tachometer

–

The tachometer is optional equipment. Components •

Alternator

•


•

Headlight Switch

•

Ignition Switch

•


•

Tachometer

Refer to Basic Gauge Diagnostic Procedure page 41. Tachometer Circuit Diagnosis Observation Inoperative

Intermittent

Inaccurate

Cause

Action



Mislocated wiring


Defective wiring


Mislocated wiring


Defective wiring


Incorrect switch position

Refer to DATCON technical manual for correct configuration.

–


50


Voltmeter Components •


•

Circuit Breaker

•

Headlight Switch

•

Ignition Switch

•


•

Voltmeter

Refer to Basic Gauge Diagnostic Procedure page 41. Voltmeter Circuit Diagnosis Observation Panel lamp does not light

Inaccurate

Inoperative

Cause

Action

Loose lamp

Inspect lamp. Tighten or replace as needed.

Burned out lamp

Replace lamp (match system voltage).

Defective dimmer switch

Replace.



Defective wiring


Defective gauge

Replace.

Defective wiring




Defective gauge

Replace.

Defective wiring




5.2.3

51

Lighting

page –

Backup Light and Alarm, Flood Light This circuit may contain an optional circuit breaker between the accessories relay and the flood light switch/backup flood relay. Components •

Accessory Relay

•

Backup Alarm

•

Backup/Flood Relay

•

Backup Light (rear of frame)

•

Cab Flood Light Switch

•

Circuit Breaker 15A

•

Flood Light

•

Ignition Switch

•

Reverse Switch

Backup Light and Alarm Circuit Diagnosis Observation Inoperative alarm

Inoperative backup light

Cause

Action



Defective alarm

Replace.

Defective backup/flood relay

Replace.

Defective wiring


Defective lamp

Replace.



Defective backup/flood relay

Replace.

Defective wiring



52


Flood Light Circuit Diagnosis Observation Inoperative

Cause

Action

Defective lamp

Replace.

Defective light switch

Replace.



Defective relay

Replace.

Defective wiring


–

Beacon Light This circuit may contain an optional circuit breaker between the accessories relay and the beacon light switch. Components •

Accessory Relay

•

Beacon Light

•

Beacon Light Switch

•

Ignition Switch

Beacon Light Circuit Diagnosis Observation Inoperative

Cause

Action

Defective beacon lamp

Replace.

Defective switch

Replace.



Defective wiring


–



53

Clearance, Marker and Tail Lights Clearance and marker lights are standard only on vehicles assembled to meet FMVSS and CMVSS requirements. Trailer marker and trailer tail light circuits are also controlled by the headlight switch via a trailer lights relay. A separate circuit breaker protects each trailer circuit. Components •

Clearance Lights

•

Headlight Switch

•

Marker Lights (Trailer) (If Applicable)

•

Marker Lights (Vehicle)

•

Parking Light Circuit Breaker 10A

•

Tail Lights (Trailer) (If Applicable)

•

Tail Lights (Vehicle)

•

Trailer Circuit Breaker 15A

•

Trailer Lights Relay

Cab Clearance and Marker Light Circuit Diagnosis Observation Individual light inoperative

All lights inoperative

Cause

Action

Defective lamp

Replace.

Defective wiring


Defective light switch

Replace.



Defective wiring



54


Trailer Clearance, Marker and Tail Light Circuit Diagnosis Observation Individual light inoperative

All lights inoperative

Cause

Action

Defective lamp

Replace.

Defective wiring




Defective headlight switch

Replace.

Defective relay

Replace.

Defective wiring


–

Daytime Running Lights Daytime running lights are optional equipment. Components •

Daytime Running Light Module

•

Headlights

•

Ignition Switch

•

Module Fuse 10A

Daytime Running Lights Circuit Diagnosis Observation Inoperative

Cause

Action

Defective lamp

Replace.

Defective fuse

Replace.

Defective wiring


Defective daytime running light module

Replace.

–



55

Dome Light Components •


•

Dome Light

Dome Light Circuit Diagnosis Observation Inoperative

Cause

Action

Defective lamp

Replace.

Defective dome light switch

Replace.



Defective wiring


–

Headlights Components •

Dimmer Switch

•

Headlights

•

Headlight Relay

•

Headlight Switch

•

Headlight Switch Circuit Breaker

•

High-Beam Indicator Light

Headlight Circuit Diagnosis Observation LH or RH headlight inoperative (high or low beam)

Both headlights inoperative

Inoperative headlight dimmer

Cause

Action

Defective lamp

Replace.

Defective wiring




Defective headlight switch

Replace.

Defective relay

Replace.

Defective wiring



Replace.

Defective relay

Replace.


56


Trailer Auxiliary Power

–

Components •

Accessory Relay

•

Ignition Switch

•

Trailer Auxiliary Switch

•

Trailer Circuit Breaker 15A

•

Trailer Wiring Disconnect

Trailer Auxiliary Circuit Diagnosis Observation No power at connector

Cause

Action



Defective wiring


–



57

Transmission Shifter/Fifth-Wheel Control and Panel Lighting Components •

Electroluminescent Lamps

•

Incandescent Lamps

•

Headlight Switch

•

Inverter

•

Parking Light Circuit Breaker 10A

•

Panel Dimmer Switch

Electroluminescence Electroluminescent (EL) lamps consist of two wafer-thin panels, one transparent and one opaque, that produce light when energized electrically. The panels are separated by an extremely narrow space. If a lamp is pinched so that the two panels come in contact, a short is created. EL lamps require an inverter to change direct current to high cycle alternating current and increase the voltage. A shorted EL lamp will cause the inverter to shut down. To isolate the defective lamp, disconnect one lead to each lamp and reconnect one at a time. A good lamp lights when connected. Transmission Shifter/Fifth-Wheel Control and Panel Lighting Circuit Diagnosis Observation Inoperative light

Cause

Action

Defective lamp

Replace.


Replace.



Defective wiring (or inverter)


–


58


Turn Signal, Brake Lights and Emergency Flasher Components •

Brake Light Switch

•

Flasher Circuit Breaker 30A

•

Stop/Tilt Circuit Breaker 20A

•

Trailer Circuit Breakers 15A

•

Turn Signal Switch

•

Turn Signal Flasher

•

Turn/Stop Light Lamps

Turn Signal, Brake Lights and Emergency Flasher Circuit Diagnosis Observation Inoperative light

Inoperative turn signal

Inoperative brake lights

Cause

Action

Defective lamp

Replace.

Defective turn signal switch

Replace.



Defective wiring


Defective turn signal flasher

Replace.

Defective turn signal switch

Replace.



Defective wiring


Defective lamp

Replace.

Defective brake light switch

Replace.



Defective wiring




5.2.4

59

Accessories and Options

page –

Accessory Relay Components •

Accessory Circuit Breakers

•

Accessory Relay

•

Ignition Switch

Accessory Relay Circuit Diagnosis Observation

Cause

Action

One accessory inoperative



All accessories inoperative

Defective relay

Replace.

Defective wiring


–

Air Dryer Components •

Ignition Circuit Breaker 30A

•

Ignition Switch

Air Dryer Circuit Diagnosis Observation Inoperative heater

Cause

Action



Defective ignition switch

Replace.

Defective wiring


–


60


Cab Tilt Pump Components •


•

Tilt Pump Control Switch

•

Tilt Pump Motor

•

Tilt Pump Solenoid

Cab Tilt Pump Circuit Diagnosis Observation Inoperative motor

Raised cab does not return

Cause

Action



Defective tilt pump control switch

Replace.

Defective tilt pump solenoid

Replace.

Defective wiring




Defective tilt pump control switch

Replace.

Defective tilt pump valve

Replace.

Motor operates — cab does not rise

Refer to Hydraulic section.

–



61

Heater/Air Conditioning (Optional) Components •

AC High Pressure Switch (Normally Closed)

•

AC Low Pressure Switch (Normally Open)

•

AC On/Off Switch

•

Blower Motor

•

Cold Control

•

Heater/AC Relay

•

Heater Resistor Block

•

Heater Switch

•

Ignition Switch

Heater/Air Conditioning Circuit Diagnosis Observation Inoperative blower

Blower operates at one or two speeds only

Cause

Action



Defective resistor

Replace.

Defective heater switch

Replace.

Defective heater/AC relay

Replace.

Defective wiring


Defective blower motor

Replace.

Defective resistor

Replace.


Replace.

–


62


Horn Components •

Horn

•

Horn Button (Switch)

•

Horn Circuit Breaker 15A

•

Horn Relay

Horn Circuit Diagnosis Observation Inoperative horn

Diminished sound

Cause

Action



Defective wiring


Defective horn button (switch)

Replace.

Defective horn relay

Replace.

Defective horn

Replace.

Defective horn

Replace.

Defective wiring


–



63

Mirrors (Heated/Motorized) Heated and Motorized (remotely controlled) mirrors are optional equipment. Components •

Mirrors

•

Mirror Heat Switch

•

Motorized Mirror Switch (Left-Hand)

•

Motorized Mirror Switch (Right-Hand)

Heated Mirror Circuit Diagnosis Observation Inoperative heater

Cause

Action




Replace.

Defective mirror

Replace.

Defective wiring


Heated Motorized Mirror Circuit Diagnosis Observation Inoperative heater

Inoperative motor

Cause

Action




Replace.

Defective mirror

Replace.

Defective wiring




Defective motor

Replace.

Defective wiring


–


64


Radio (Optional) Components •

Accessory Relay

•

Radio

•

Radio Circuit Breaker 15A

•

Speakers

Radio Circuit Diagnosis Observation Inoperative radio

Poor performance

Cause

Action



Defective relay

Replace.

Defective speakers

Repair or replace.

Defective radio

Replace.

Defective wiring


Defective antenna

Repair or replace.

Defective speakers

Repair or replace.

Defective radio

Replace.

Defective wiring


–



65

Windshield Washer The windshield washer is optional equipment. Components •

Accessory Relay

•

Ignition Switch

•

Windshield Washer Motor

•

Windshield Washer Switch

Windshield Washer Circuit Diagnosis Observation Inoperative

Cause

Action

No fluid

Add fluid as needed.

Hose or nozzle plugged

Clean as needed.



Defective relay

Replace.

Defective motor

Replace.

Defective wiring


–


66


Windshield Wipers Windshield wipers are optional equipment. Components •

Circuit Breaker 8A

•

Ignition Switch

•

Wiper Motor

•

Wiper Relay

•

Wiper Switch

Windshield Wipers Circuit Diagnosis Observation Inoperative

Operate slowly

Operate at one speed

Do not park

Cause

Action

Linkage binding


Defective switch

Replace.



Defective relay

Replace.

Defective wiring


Linkage binding


Low battery charge

Recharge battery or replace as needed.

Defective wiring


Defective motor

Replace.

Defective switch

Replace.

Defective motor

Replace.

Linkage binding


Defective switch

Replace.

Defective motor

Replace.


5.3 Hydraulic – 5 Diagnostic Procedures

5.3

67

Hydraulic

page –

Boom Components •

Control Valve

•

Filter

•

Boom Lift Cylinders

•

Hydraulic Pump

•

Hydraulic Relief Valve

•

Reservoir

•

Wet Line Kit Connection

Maximum Pressure — Hydraulic Relief Valve Vehicle

Maximum Pressure

All Ottawa 4x2 and 6x4 tractors with 5-inch cylinders

2000 PSI

WARN IN G Do NOT feel for leaks. Hydraulic fluid under high pressure may have knife-like characteristics. Failure to heed this warning could result in severe personal injury.

Boom Diagnosis Observation Cylinders leak down

Cause

Action

Damaged seals or cylinder wall

Replace cylinder.

Worn control valve

Replace.

Drops slightly, momentarily before lifting

Load check seat or control valve spring malfunction

Clean or replace as needed.

Lifts slowly

Pump inlet restricted

Remove restriction.

Worn pump

Replace.

Internal leakage in control valve

Replace.

Internal leakage in cylinders

Replace.

Valve actuating cable/lever not centered

Adjust. Unbind. Lubricate as needed.


68


Observation Stalls under load

Inoperative

Jerky, erratic movement

Cause

Action

Low fluid level


Low relief valve setting

Adjust or replace.

Extraordinary internal leakage

Test circuits to isolate point of leakage.

Extraordinary pump wear

Replace.

Seized or damaged lever or control cable

Repair as needed.

Extreme internal leakage

Test circuits to isolate point of leakage.

Air in system

Inspect fittings and seals. Replace as needed.

–

Cab Tilt Components •


•

Tilt Pump Control Switch

•

Tilt Pump Motor

•

Tilt Solenoid

D ANGER Do NOT work under the raised cab before ensuring that the cab safety prop is locked in position. Failure to heed this danger could result in severe personal injury or death. Cab Tilt Diagnosis Observation

Cause

Action

Inoperative pump

Electrical

See Electrical section.

Motor runs — cab does not tilt

Low fluid


Line leakage

Locate and repair.

–



69

Power Steering Components •

Power Steering Gear

•

Power Steering Pump

•

Reservoir

The following guide covers symptoms that may be remedied by adjustments outside of the steering gear. For symptoms indicating problems within the steering gear, consult the manufacturer's service manuals. Power Steering Diagnosis Observation Hard steering

Cause

Action

Overloaded axle

Review GAWR specifications. Reload as needed.

Underinflated tires

Inflate correctly.

Front end misaligned

Align front end.

Worn linkages

Replace as needed.

Damaged king pins or tie rods


Steering column binding

Repair as needed.

Weak fluid flow rate

Review manufacturer's manual or replace pump.

Wheel cuts restricted

Axle stop setting

Reset.

Steering-to-frame interference

Drag link adjustment

Reset.

Pitman arm adjustment

Reset.

Air in system

Bleed system.

Low fluid level


Inconsistent steering pressure


70

5.4 Mechanical – 5 Diagnostic Procedures

5.4

Mechanical

page –

Brakes Components •

Brake Drums

•

Brake Shoes

Brakes — Mechanical Diagnosis Observation Pulls to one side

Insufficient braking power

Slow application

Cause

Action

Poor front end alignment

Inspect and repair as needed.

Unequal tire pressure or tread

Inspect. Repair or replace as needed.

Uneven vehicle loading

Inspect. Redistribute load as needed.

Loose front wheel bearings


Low air system pressure

Inspect for leaks. Repair or replace as necessary.

Poor adjustment, poor lubrication or worn brake linings

Inspect. Adjust, lubricate and repair as needed.

Defective components (e.g., slack adjusters, push rods, cams)


Air line(s) restricted


Poor adjustment or poor lubrication

Inspect. Adjust or lubricate as needed.



Treadle valve leaking


Brake chamber leaking


Spring brake chamber leaking




Observation Slow release

Service brakes do not release

Brakes grab

Uneven braking

Cause

71

Action

Treadle valve return slowed by dirt and grime

Clean and lubricate as needed.





Valve exhaust ports (e.g., treadle, quick release, relay) plugged


Broken or weak shoe or chamber spring


Treadle valve return slowed by dirt and grime

Clean and lubricate as needed.



Valve exhaust ports (e.g., treadle, quick release, relay) plugged


Grease or oil on linings

Determine source of grease or oil. Repair as needed. Clean drums and replace shoes.

Drum out of round


Defective valves


Actuating linkages (e.g., slack adjusters, push rods) bind




Grease or oil on linings

Determine source of grease or oil. Repair as needed. Clean drums and replace shoes.

Broken diaphragm or return spring


Drum out of round


Brake chamber diaphragm leaking



72


Observation

Cause

No pressure buildup

Action Refer to Brake Air System Diagnosis table.

Low air pressure warning Pressure drops quickly: engine stopped, brakes applied Pressure drops: engine stopped, brakes applied Pressure does not reach normal Pressure builds too slowly Pressure too high No brakes


5.5 Pneumatic – 5 Diagnostic Procedures

5.5

73

Pneumatic

page –

Brakes — Air System A DOT/EPA system includes three reservoirs: primary, front and rear. Off-highway vehicles have only two reservoirs: supply and service. Components •

Air Compressor

•

Air Control Valve

•


•

Antilock Modulator Valve (Optional)

•

Automatic Slack Adjusters

•

Bobtail Proportioning Relay Valve (Optional)

•

Brake Valve (treadle)

•

Check Valve

•

Double Check Valve

•

Front Brake Chambers

•

Governor

•

Low Pressure Indicator

•

Pressure Protection Valve

•

Pressure Relief Valve

•

Quick Release Valve

•

Rear Brake Chambers

•

Reservoirs (DOT/EPA: primary, front and rear) (Off-Highway: supply and service)

•

Stoplight Switch

•

Tractor Protection Valve

Brakes — Air System Diagnosis Observation Frequent air dryer purging (cycling)

Cause

Action

Excessive system leakage

Inspect system connections. Repair or replace as needed.

Defective internal check valve


Defective governor

Test. Adjust or replace as needed.

Purge valve leaks


Compressor unloader leaks

Slight leakage permitted. Uncover inlet cavity and inspect piston. Repair or replace unloader as needed.


74


Observation Water in reservoirs

Dryer safety valve discharging

No pressure buildup (continuous exhaust at dryer purge valve)

Fails to purge

Cause

Action

Desiccant saturated

Replace desiccant cartridge. Refer to Medium Duty Truck Unit Repair Manual.

External charge air did not pass through air dryer

Ensure charge air enters filter valve at compressor.

Air dryer not purging

Inspect purge valve. Refer to Medium Duty Truck Unit Repair Manual.

Purge time too short

Refer to Frequent Purging (Cycling) above.

Desiccant cartridge plugged or saturated

Replace desiccant cartridge. Refer to Medium Duty Truck Unit Repair Manual.

Defective internal check valve


Defective hose, tubing or fittings between dryer and main supply reservoir

Inspect hose, tubing and fittings for holes, kinks and other restrictions. Repair or replace as needed.

Purge valve leaking

Inspect. Repair or replace air dryer as needed. Refer to Medium Duty Truck Unit Repair Manual.

Defective governor


Purge control line connected to reservoir or governor exhaust port

Connect to governor unloader port.

Defective electrical circuitry

Test. Repair or replace as needed.

Inlet and outlet air connections reversed

Reconnect lines correctly.

Defective check valve between dryer and first reservoir

Test. Repair or replace as needed.

Kinked or blocked discharge line

Straighten, clean, repair or replace as needed.

Excessive air system leakage


Broken, kinked, plugged or disconnected purge control line

Test line — compressor unloaded.

Defective purge valve

Inspect. Repair or replace air dryer as needed. Refer to Medium Duty Truck Unit Repair Manual.



Observation Desiccant expelled through purge valve

Low air pressure warning

Pressure drops quickly: engine stopped, brakes applied

Pressure drops: engine stopped, brakes applied

Cause

75

Action

Air dryer vibration


Defective desiccant cartridge


Defective compressor piston rings

Inspect supply air. If oil is present, repair or replace compressor as needed. Refer to Medium Duty Truck Unit Repair Manual.

Defective electrical circuitry


Half of dual system failed

Inspect gauges. Repair or replace failed components as needed.

System failed

Inspect for leaks. Repair or replace failed components as needed.

Defective governor


Defective compressor


Excessive air system leakage


Treadle valve leak


Brake chamber leak


Lines or fittings leak


Treadle valve leak


Lines or fittings leak


Spring chamber leak



76


Observation

Cause

Pressure does not reach normal

Pressure builds too slowly

Pressure too high

No brakes

Action

Reservoir drain cocks open

Inspect and close as needed.



Poor governor adjustment

Inspect. Adjust, repair or replace as needed.

Defective air pressure gauge


Defective air compressor


Engine idle too slow




Defective air compressor


Defective air pressure gauge


Poor governor adjustment

Inspect. Adjust, repair or replace as needed.



Air line(s) restricted or broken


Defective treadle valve


–

Cab Air Suspension Components •

Cab Leveling Valve

•

Cab Shock Absorbers

Cab Leveling Valve and Shock Absorber Diagnosis Observation

Cause

Action

Cab leveling too fast or too slow

Clogged leveling valve

Inspect. Replace as needed.

Uncontrolled cab bounce

Shock absorbers worn

Inspect. Replace as needed.


5.6 Structural – 5 Diagnostic Procedures

5.6

77

Structural

page –

Chassis Components •

Frame

•

Fuel Tanks

•

Otto-Ride

NOTE Frame rails are not serviceable. For repair or replacement, call Parts and Service, Ottawa Truck. Frame rails that are out of shape must be straightened and properly aligned to restore the vehicle to maximum capacity and safe performance. If the cause of misshapen rails is overloading, continuing safely in such heavy service requires that the rails be reinforced after reshaping and alignment. If the failure is the result of too many or improperly located holes in one or both rails, the frame should be replaced unless safe practice will permit adding reinforcement. Always follow the guidelines for adding reinforcement to the rails and for drilling holes in the rails.

WARN IN G Welding produces so much heat that there is a risk of changing the physical properties of the steel in the frame rails. If the vehicle may be economically restored to service by means of welding, call Parts and Service, Ottawa Truck, or ensure that best welding practices are rigorously followed so as to avoid changing the properties of the steel. Failure to heed this warning may result in severe property damage.

WARN IN G Do NOT cut the rails or holes in the rails using a welding torch. Do NOT drill holes in top or bottom rail flanges. Failure to heed this warning may result in severe property damage.


78


Frame Diagnosis Observation Cracked rails

Sagging rails

Cause

Action

Loose bolts

Install larger bolts. Refer to instructions for repairing cracked rails elsewhere in this manual. Reinforce rail.

Overloading

Refer to instructions for repairing cracked rails elsewhere in this manual. Reinforce rail.

Overloading

Straighten, reinforce and align the rails, or replace the frame as needed.

Uneven loading Holes in rail flange Too many rail web holes Rail web holes too close together Four or more rail web holes aligned vertically Welds on flange No filler blocks Rail web holes cut with torch Notches anywhere in rails Vehicle fire Vehicle collision Equipment added beyond vehicle capacity Buckled rails

Fifth wheel raised to maximum while maneuvering a loaded trailer Equipment added beyond vehicle capacity Load shift (e.g., surging liquid) in a loaded trailer Vehicle fire Vehicle collision Rails weakened by added holes, notches, extraordinary welding or cutting




Observation Misaligned rails

Cause

79

Action

Misaligned axle or weak spring. These conditions may give the appearance of misaligned rails.

Inspect. Repair as needed.

Vehicle collision


Towing load attached to one rail Operating over rough terrain Improper tracking

Improper front end alignment

Align the front end.

Misaligned rails


Misaligned axle

Align the axle.


80

Notes


6.1 Checklists – 6 Scheduled Maintenance

6 Scheduled Maintenance

mm mm mm mm mm mm

6.1

Checklists

page –

Lubrication Points 1. Coolant/Antifreeze

16

1

15

2 3 ** 4*

14 *

2. Engine Oil

5*

3. Slack Adjusters Brake Cam Pivot 4. Front Axle King Pins 5. Tie Rod Ends 6. Transmission Fluid 7. Diesel Fuel

13 *

6

12

7

8. Universal Joints 9. Rear Axle Differential 10. Driveline Slip Yoke

8

11. Hydraulic/Steering Fluid

11

12. Cab Suspension Latch

10

13. Spring Shackle Pins 14. Front Wheel Bearings 15. Drag Link Ends 16. Steering Slip Joint OTT0001

9

* BOTH SIDES ** BOTH SIDES FRONT AND REAR Chassis Lubrication Diagram — Left-Hand Drive 20

17. Boom Pivot

21

18. Boom Cylinder Bearings

19 *

19. Fifth-Wheel Pivot

18 *

20. Fifth-Wheel Top Plate 21. Fifth-Wheel Jaws Side Door Hinge (not shown)

17 * * BOTH SIDES Boom and Fifth-Wheel Lubrication Diagram

OTT0002

Rear Door Upper Rollers (not shown)


81

82

page –


Daily Inspection Checklist At each inspection, add fluids and lubricants as indicated. Repair all leaks. Replace cracked, damaged or worn parts. ❒ Fuel tank ❒ Engine oil level (engine stopped) ❒ Coolant level ❒ Windshield washer fluid level (if applicable) ❒ Fuel water separator ❒ Transmission fluid level (engine running) ❒ Hydraulic fluid level (boom full down) ❒ Front wheel hub oil level (if applicable) ❒ Engine belt condition and tension ❒ Steering system ❒ Hoses and wiring ❒ Exhaust system ❒ Drain air tanks ❒ Trailer lines, glad-hand seals and trailer cord ❒ Catwalk, boom deck and grab handles ❒ Lift cylinders ❒ Cab doors and latches ❒ Cab hold down latch ❒ Fifth-Wheel, secondary lock, jaws and cylinder operation ❒ Boom control lever operation ❒ Tire condition ❒ Oil pressure alarm and gauge operation ❒ Transmission shift lever operation ❒ Backup alarm operation ❒ Windshield wiper and washer operation ❒ Horn ❒ Radio equipment ❒ Gauges and dash lights ❒ Dome lights ❒ Turn signals ❒ Hazard lights ❒ Headlights ❒ Marker lights ❒ Backup lights ❒ Brake lights ❒ Strobe light (if applicable) ❒ Auxiliary backup lights Maintenance manual Ottawa 4x2, 6x4


83

❒ Clean the cab interior. ❒ Clean the windows. ❒ Clean and adjust the mirrors. page –

Every 250 Hours of Operation Perform the inspections listed in column A of the chart. Refer to the Preventive Maintenance Forms page 84. These service procedures must be performed after every 250 hours of operation or every month, whichever occurs first. page –

Every 500 Hours of Operation Perform the inspections listed in column B of the chart. Refer to the Preventive Maintenance Forms page 84. These service procedures must be performed after every 500 hours of operation, or every three months, whichever occurs first. page –

Every 1,000 Hours of Operation Perform the inspections listed in column C of the chart. Refer to the Preventive Maintenance Forms page 84. These service procedures must be performed after every 1,000 hours of operation. page –

Every 2,000 Hours of Operation Perform the inspections listed in column D of the chart. Refer to the Preventive Maintenance Forms page 84. These service procedures must be performed after every 2,000 hours of operation.


84


–

OTT0003

Preventive Maintenance Forms

Preventive Maintenance Form — Non-Synthetic Transmission Lubrication


85

OTT0004


Preventive Maintenance Form — Synthetic Transmission Lubrication with High Capacity Filters


86

–


Preventive Maintenance Technique The following is more detailed information for preventive maintenance. See the Lubrication Points page 81 provided in this manual. Refer to the Preventive Maintenance Forms page 84 for additional scheduling. The hourly time limits described in this manual are absolute maximums. Harsh vehicle usage may dictate shorter intervals. Inspect frequently to discover where changes may be necessary. Fuel, Filters, Fluids and Lubricants The engine, transmission and axle manufacturers provide maintenance information and specify fluids and lubricants to be used in their products. Comply with the original equipment manufacturer’s specifications in order to maintain warranty coverage. Follow the periodic checklists as indicated. Fill reservoirs as necessary using specified fluids. When adding, use the same fluid as is in the reservoir. If the fluid is unknown, drain and replace it according to specification. Use only the fuel, coolant, coolant additives and lubricants specified by the engine manufacturer. Follow the engine manufacturer’s specification for the coolant and water ratio or maintain engine coolant freeze protection at approximately −34°F. Determine the reason for lost fluid. Repair as necessary. The Kalmar Parts Catalog is customized to the vehicle. Refer to this catalog for filter part numbers. Kalmar recommends API Grade 1 grease, any high quality lithium-based grease, or a base oil with a Timken 40 minimum rating for use in axles. Install the same lubricant as originally installed in the axles. Do not use lithium grease on front axles equipped with “WET” wheel seals. The front hubs must be inspected after every 250 hours of operation. Power steering, the boom lift and the cab tilt mechanism all use hydraulic fluid stored in a single tank mounted on the rail. A vehicle being operated in a severe application may require shorter intervals between changes. The system filter is on the hydraulic tank.

–



87

Cab Interior Neutral Start — Move the gear selector to any position other than “N” and attempt to start the engine. The engine should not crank with the selector in any position other than “N.” All Gauges — With the engine running, verify that all gauges are functional. Low Air Buzzer and Light — Apply and release the brake pedal until air pressure drops below 90 PSI. At that point, the low air buzzer and dash warning light should come on. Windshield Wiper Operation — Turn on the windshield wiper and confirm full and smooth travel of the wiper arm. Listen for noises that might indicate a worn wiper motor. Windshield Washer Operation (If Applicable) — Depress the washer button and confirm the flow and pattern of the washer fluid. Throttle Operation — Depress and release the foot throttle and check for binding and ease of operation. Horn(s) Operation — Sound electric and air horns (if applicable) to confirm proper operation. Air System — Start the engine and run at fast idle. Maximum system pressure should be between 120 PSI and 130 PSI. Air System Leak Down — Disconnect the glad hands from the trailer. Run the engine at fast idle and allow air pressure to stabilize at 120 PSI for at least one minute. Shut off the engine and observe the dash gauge(s) for two minutes. The drop in pressure should not exceed 2 PSI over the two-minute period. Backup Alarm — With the engine running, move the gear selector to reverse and listen for the backup alarm. HVAC System — •

Blower Motor Operation With the key on, ensure that the blower motor operates at each position of the blower speed switch.

•

Temperature Control Confirm proper operation of the temperature control switch.

•

Defroster Operation With the engine running and the defroster control turned on, confirm air flow from the defroster vents.

•

Air Conditioner Operation With the engine running and the air conditioner control turned on, confirm cooled air flow from the vents.


88


•

Auxiliary Fan(s) (If Applicable) With the key on, turn on the auxiliary fans and confirm operation.

Fifth-Wheel Unlatch Control — With system air pressure above 100 PSI, confirm that the fifth-wheel jaws unlatch when the dash control is activated. Boom — With the engine running at fast idle, activate the boom control and verify full extension and retraction. Windows — Confirm that all regulated and sliding windows open and close fully. Seat Belt Operation — Verify that the seat belt latch fastens and unfastens properly. Rear and Side Door Latch Operation — Operate the side door latch from inside and outside the cab to ensure proper operation. Dome Light Operation — With the key on, turn on the cab dome light and confirm operation. All Glass and Mirrors — Inspect all glass and mirrors for cracks and breaks. Fire Extinguisher Charge (If Applicable) — If the vehicle is equipped with a fire extinguisher, confirm that it is properly charged. –

Cab Down — Exterior Side Door Hinges — Inspect the door hinge for wear and damage. Cab Access Steps and Handles — Inspect all steps and grab handles for proper mounting and the absence of cracks. Heater/AC Filter — Remove the HVAC filter and vacuum or blow clean with low-pressure air. Rear Door Roller/Slide Adjustment — Inspect the roller and slide adjustment for wear and damage. Glad-Hand Seals and Trailer Air Lines — Inspect seals for tears and wear. Check air lines for kinks or cracks. Trailer Light Cord (If Applicable) — Inspect light cord for cuts and abrasions. As the lights of the truck are checked, confirm that a trailer connected with the light cord also has lights. This can be done either with a trailer connected or with a “test box”. Headlights/Marker Lights — Start the engine, turn on light switches and confirm lights are burning. Turn Signals — With the key on, activate the turn signal switch and the flasher to confirm that the turn signals are working. Strobe Light (If Applicable) — With the key on, turn on the strobe light to confirm its operation. Maintenance manual Ottawa 4x2, 6x4


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Spotlights — With the key on, turn on the spotlight(s) to confirm its operation. Wiper Blades — Inspect wiper blades for tears or excessive wear. Windshield Washer Fluid Level (If Applicable) — Fill the washer bottle as necessary. –

Cab Up Cab Tilt Pump — Pull the cab release cable and activate the cab tilt switch. The cab should rise. Cab Safety Prop — Inspect the cab safety prop that encloses the cab lift cylinder. It should drop freely into place to support the cab when it is in the raised position. The lower cab cylinder pin and bracket should be inspected for signs of fatigue. Cab Suspension and Latch — Inspect the linkages of the suspension system for excessive wear and proper alignment. Inspect the air bag for leaks or signs of abrasion. Inspect the lock jaw for excessive wear and proper operation. Intake Ducting for Leaks — Inspect all engine clean air tubes and hoses for leaks. All clamps should be checked for proper torque and all joints should be properly aligned. Radiator for Leaks — Inspect the radiator core and tanks for signs of coolant leaks. Radiator Mounts — Inspect the radiator mounts for wear or excessive looseness. Coolant Level and Concentration — Check the cooling system level. Coolant should be visible in the radiator sight glass. It is not necessary for the coolant to be at the top of the sight glass. Test and maintain the proper antifreeze level of concentration as outlined in the appropriate engine operator’s manual. Coolant Additive (If Applicable) — Using the appropriate test method for the diesel coolant additive (DCA) or supplemental coolant additive (SCA) being used (e.g., Nalcool), maintain the recommended level of concentration as outlined in the applicable engine operator’s guide. Change Engine Coolant — Flush the cooling system and replace with clean coolant of the appropriate concentration. Coolant Hoses and Clamps — Inspect all hoses for abrasion, cracks, holes and routing. Check all clamps for proper torque. Fan Clutch for Operation (If Applicable) — Run the engine to confirm that the fan clutch engages at the proper temperature. Engine Cooling Fan for Cracks — Shut the engine off if running. Inspect fan blades for signs of cracking.


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Engine Belts and Tensioner — Inspect belt(s) for cracking and wear. The belt tensioner should be checked for proper operation. Change Engine Coolant Filter (If Applicable) — Replace the engine coolant filter. A filter containing the proper SCA should be used to maintain the specified concentration level. Engine and Transmission for Leaks — Perform a visual inspection of the engine and transmission looking for fluid leaks visible from above. Drain Fuel/Water Separator — Open the drain valve on the fuel/water separator and allow water to drain from the filter. Change Fuel/Water Separator — Replace the fuel filter following the instructions in the engine operator’s manual. Air Restriction Gauge (If Applicable) — Record the reading on the gauge, reset, start the engine, run to high idle and shut off the engine. If the reading remains zero, the gauge may be defective or the intake piping has a leak. Discover the cause and repair or replace parts as necessary. If the initial gauge reading indicates that the filter should be changed, do so at this time. Change Air Filter — The air filter should be changed as necessary. If the truck is equipped with a restriction gauge, replace the filter when the gauge indicates. Change Air Dryer Desiccant (If Applicable) — The desiccant should be changed as necessary. Change as soon as water is evident when the system air tanks are drained. Exhaust System — Visually inspect all of the exhaust system components for leaks and/or damage. Transmission Fluid Level — With the engine running, use the transmission dipstick to check the fluid level per the guidelines in the transmission operator’s manual. Clean Transmission Breather — Confirm that the breather, located on top of the transmission, is clean and the passage is open. Do not spray directly with high pressure or cleaning solvents. Tighten Cab-to-Deck Mounting Bolts — Tighten the cab-to-deck fasteners. –



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Under Vehicle Steering Gear — Inspect the steering gear for fluid leaks and excessive play. Inspect the steering linkage for wear or looseness. Brake Linings and Drums — Visually check linings and drums for wear and cracks. If the lining is 0.25 inch thick or less in any location, the shoes should be replaced or relined. Leaf Springs — Inspect leaf springs for cracking or excessive deflection. Inspect spring pins and shackles for wear. Shock Absorbers (If Applicable) — Inspect shock absorbers for leaks. Tighten Front Axle Mounting Bolts — Tighten front axle mounting bolts. Tighten King Pin Draw Key Nuts — Tighten steer axle king pin draw key nuts. Hydraulic Pump — Inspect the hydraulic pump for leaks. Starter Mounting and Connections — Confirm that starter mounting bolts are tight. Inspect electrical connections for good contact at starter terminals. Engine and Transmission for Leaks — Perform a visual inspection of the engine and transmission looking for fluid leaks visible from below. Change Engine Oil and Filter — Drain and replace the engine oil. Use oil that meets or exceeds the minimum specifications in the engine operator’s manual. Replace the oil filter. Change Transmission Filters — Follow transmission manufacturer's procedures.

NOTE This does NOT include the pan screen. The screen should only be replaced during overhaul. Change Transmission Fluid — Drain and replace the transmission fluid. Use fluid that meets or exceeds the minimum specifications provided in the transmission operator’s manual. Engine and Transmission Mounts — Tighten the engine and transmission mounts. Inspect isolator material and replace if deteriorated. Wheel Seals for Leaks — Inspect the front and rear hubs for signs of oil leaks. Replace if leaking. Rear Axle Breather — Ensure that the rear axle vent turns freely. Differential — Inspect the rear axle housing for signs of leaks. Repair as necessary.


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Differential Oil Level — Check the differential oil level per the component manufacturer’s instructions. Change Differential Oil — Drain and replace differential oil. Use oil that meets or exceeds the minimum specifications of the component manufacturer. Lift Cylinders — Inspect cylinders for leaks. Repair as necessary. Otto-Ride Rubber Isolator (If Applicable) — Inspect the isolator for signs of cracking or loss of elasticity. Replace as necessary. Rear Axle Mounting Bolts — Tighten rear axle mounting bolts. –

Chassis Front Wheel Bearings — Raise and support the front axle. Check for excessive play in wheel bearing. Front Axle Oil Level (If Applicable) — Check the oil level in the front axle hubcaps. Fill to proper level as necessary. Front Wheel Bearings (If Applicable) — Remove front hubs and repack the bearings using grease that meets or exceeds the minimum specifications of the component manufacturer. Battery Cables and Holddowns — Inspect the battery for signs of abrasion or breaking. Repair and reroute as necessary. Ensure that the batteries are properly secured. Batteries — Inspect the batteries for signs of damage. Replace as necessary. Battery Cable Connections — Remove the cable terminals from batteries, clean connections, reattach cable terminals. Battery Box Cover Holddowns — Check the bolts or rubber latches to ensure that the battery box cover is secured. Air Tanks — With the air system charged, open each manual drain until all moisture is removed from the system. All Wheel Nuts — Inspect all wheel nuts for signs of wear or damage. Wheels — Inspect all wheels for signs of damage including oversized holes and cracks. Tires — Inspect tires for damage and wear. Adjust to the air pressure specified for the tire. Rear Axle Planetary Housing (If Applicable) — Check and adjust the lubricant level in the planetary housings per the component manufacturer’s instructions. Platforms — Inspect the platforms for proper mounting and the absence of cracks and trip points. Frame — Inspect the frame rails and cross members for cracks and bending.



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Mud Flaps/Fenders (If Applicable) — If equipped with mud flaps and or fender, inspect these items for proper mounting and damage. Change Hydraulic System Filter — Remove and replace the external hydraulic filter. Hydraulic Fluid Level — Start the engine, raise and lower the boom twice to ensure that the system components are filled. Lower the boom to full down position, shut off the engine and check the fluid level on the tank gauge. Fill as necessary. Change Hydraulic Fluid — Drain the hydraulic tank and refill with the specified hydraulic fluid. Hydraulic Tank Vent — Remove dirt collecting around the vent and ensure that the vent is clear. Cab Hinge Pins and Bushings — Inspect pins and bushings for wear or damage. –

Lubrication Rear Door Rollers — Inspect upper rollers. Replace if binding or damaged. Lubricate. Hood Hinge — Inspect the hood hinge for wear and damage. Lubricate. Steering Slip Joint — Inspect the slip joint for wear or damage. Lubricate. Steering U-Joints — Inspect the u-joints for wear or damage. Lubricate. Steering Lube Points — Inspect king pins, tie rod ends and drag link ends for wear or damage. Lubricate. Slack Adjusters — Inspect the brake slack adjusters for wear or damage. Measure the brake actuator stroke. If this measurement exceeds the component manufacturer’s specification, check the brake lining and adjuster to determine the cause of the excessive stroke and repair as necessary. Leaf Spring Pins and Bushings — Inspect spring pins, hangers and pin bushings for wear or damage. Lubricate. Driveline U-Joints — Inspect driveline and u-joints for wear or damage. Lubricate. Fifth-Wheel Jaws — Remove dirt and excessive grease from the fifth-wheel jaws. Using a fifth-wheel jaw gauge, measure the free play. If free play exceeds 1/8 inch, determine the cause and repair or replace the jaws per the component manufacturer’s recommendation. Fifth-Wheel Top Plate — Clean and inspect the fifth-wheel top plate for cracks or other damage. Apply grease to the surface of the top plate.


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Fifth-Wheel Pivot Pins — Inspect fifth-wheel pivot pins for wear or damage. Lubricate. Boom Pivot Bearings — Inspect boom pivot bearings for wear or damage. Lubricate. Boom Cylinder Bearings — Inspect boom cylinder bearings for wear or damage. Lubricate. Hydraulic Pump Drive (If Applicable) — (Applies only to trucks built prior to March 2007) Remove the hydraulic pump from the PTO. Inspect the splined coupling shaft for wear. On units equipped with a zerk fitting, removal of the PTO is not necessary. Lubricate. Otto-Ride Pivot Points (If Applicable) — Inspect all Otto-Ride pivot points for wear or damage. On Otto-Ride systems equipped with a single point lube system, inspect lube lines to ensure delivery of lubricant to all points. Depending on the type of lube system, lubricate the single point or each pivot point. Autolube Reservoir — If the vehicle is equipped with an automatic lubrication system, inspect all lubrication points for sufficient grease. Fill the system reservoir with the proper type and quantity of grease per the component manufacturer’s recommendation. –

Test Drive Overall Operation — Start and drive the vehicle. Test the operation of all systems and components.


7.1 Chassis – 7 Repair Procedures

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7 Repair Procedures 7.1

Chassis

7.1.1

Frame Damage

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Damage Analysis This section is not intended to cover the causes of all possible frame problems; however, it should be of valuable assistance in preparing complete, concise reports. The purpose of this information is to emphasize the fact that frame damage doesn’t just happen, there is always a cause or reason. An example of this would be a vehicle involved in a collision. The reason for damage in this case is apparent; however, other damages can be encountered where the reasons are not so apparent. Three types of frame damage can be classified as follows: 1. Collision 2. Excessive bending moment 3. Localized stress concentration Damage caused by collision should be repaired using proper methods and reinforcement. Excessive bending moment damage is caused by overloading, improper weight distribution, or misapplication of the vehicle. Excessive bending moment damage will occur at different areas on various types of vehicles. The effects of excessive bending moment will vary by type of vehicle.

7.1.2

Making Reinforcements

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General Information

C AUTION When welding on a Kalmar truck: 1. Always disconnect the wiring at the battery terminals and ECUs. 2. The ground for the welder should always be attached as close as possible to the work area. 3. Failure to adhere to these cautions can result in permanent damage to the electrical system.


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In general, when making reinforcements of any type, observe the following practices. 1. Contact the Kalmar Engineering Department for design approval. 2. Taper reinforcement plates to avoid abrupt changes in section modulus. Angles at the edge of a reinforcement plate should be less than 45 degrees. 3. When reinforcement plates are shaped by use of a cutting torch, all cracks, nicks, and burrs must be removed from the edges by grinding. Burrs must also be removed from the edges of holes. 4. Make reinforcements long enough so that they can be tapered and still extend beyond the critical area. –

Attachment Reinforcements must be attached with grade 8 bolts, locknuts and hardened washers on both ends of the bolt. This provides a good torque surface to maintain tight bolts. Avoid attaching reinforcements by welding. (In some cases, welding may be acceptable. Such cases include the plug weld used on strap or web reinforcements.) Bolt holes that are enlarged or irregularly worn may be reamed to accept the next larger bolt diameter. For critical areas, body-fit bolts require reaming the hole to a nonstandard size to effect an interference fit for the bolt. Whenever possible, use existing frame holes rather than drill new ones. In general, when attaching reinforcements to the frame, use bolts and observe the following: 1. Use existing holes, if possible. 2. Do not drill holes in the frame flange. 3. Holes should be made as close to the neutral axis (halfway between the flanges) as possible. 4. Bolt holes should be no larger than those already existing in the frame. 5. No more than three holes should be on a vertical line of the web. 6. Holes should be at least 3/4 inch apart. 7. Holes in a reinforcement plate should be at least two times the material thickness from the edge of the plate.



7.1.3 page –

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Repairing Cracks in Steel Rails or Cross Members

Types of Cracks The straight crack and the sunburst crack are the two common types. The straight crack will normally start from the edge of a flange. It will progress across the flange and through the web section of a rail. Ultimately, it will continue through the other flange. This type of crack may result from high concentrations of stress in small areas of the frame, excessive bending moment, and torsion loading. Sunburst cracks will radiate out from a hole in the web section of a rail or cross member. They are caused by high loads being applied at a mounting bracket or cross member, which is not securely or properly attached to the rail. If cracks occur to both the rail and reinforcement of a steel frame, they must be repaired separately. The flanges must react independently to prevent localized stress concentrations. Use a copper spacer between the flanges of cracked base rail flanges and reinforcement flanges. Cross member mounting flange cracks may be repaired in the same manner as side rail cracks. However, the weld bead should be built up to provide a good smooth radius. If extensive damage is incurred to a cross member, the cross member should be replaced. It may be necessary to align the frame and level the rails before repairing the frame. The following procedure should be used to repair cracks in a rail, reinforcement or cross member. 1. Remove any equipment that will interfere with access to the crack. 2. Locate the extreme end of the crack and drill a 1/2-inch hole. 3. V-grind the entire length of the crack from the starting point to the hole at the extreme end. The angle of the “V” will depend on the welding process used. 4. The bottom of the crack should be opened up 1/16 inch to allow good penetration of the weld. (A hacksaw blade may be used for this.) 5. Weld with the proper electrode and proper welding techniques. 6. Grind the weld smooth on both the inside and outside of the rail or cross member. Be extremely careful to eliminate weld buildup or notches on the edge of the flange.


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7.1.4

Front Springs and Pins

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Springs and Pins Removal 1. Park the vehicle on level ground and chock the rear wheels. 2. Raise the front of the vehicle high enough to relieve all tension on the front springs while allowing the front wheels to remain in contact with the ground. Place jack stands under the frame to support the front of the vehicle in the raised position.

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3. With the vehicle raised, chock the front wheels to prevent the axle from moving as the springs are removed in the following steps. 4. Remove the nut and washer from the pin (1) at the front spring eye and the nuts and washers from the shackle pins (2) at the rear of the spring. 5. Using a suitable pry bar, remove the pins (1, 2) securing the front spring to the frame brackets. 6. Support the spring and remove the nuts, washers and bolts (3) securing the bump stop, spring assembly and spacer to the front axle. 7. Remove the bump stop, spring assembly and spacer. 8. Repeat steps 4 through 7 to remove the spring assembly at the opposite side.

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Springs and Pins Installation

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2. Align the spring eye with the front frame bracket and install the pin (1), washer and nut. Tighten the nut to specification.

C AUTION Use care to avoid damage to the spring pins as they are being installed.

3. Install the hangers, pins (2), washers and nuts to secure the rear of the spring to the frame bracket. Tighten the nuts to specification.

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1. Place the spacer, spring assembly and bump stop in position on the front axle and install the mounting bolts (3), washers and nuts to secure the assembly to the axle. Tighten the bolts and nuts to specification.

4. Repeat steps 1 through 3 to install the spring assembly at the opposite side. 5. Remove the jack stands and lower the vehicle to the ground.

NOTE After 50 hours of operation — Check and retighten the bolts, if necessary.


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7.2 Cab/Deck – 7 Repair Procedures

7.2 7.2.1

Cab/Deck Air Ride Suspension (Three-Point)

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Cab Suspension Assembly Removal 1. Park the vehicle on firm level ground. 2. Raise and support the cab. 3. After the cab is raised and supported, briefly press the cab “tilt” switch to the “DOWN” position. This will evacuate extra fluid from the cylinder. 4. Turn off the air supply to the cab suspension by turning the small “T-handle” valve (1) clockwise. It is located next to the latch bar plate on the bottom of the deck. DSC2453

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5. Disconnect and cap the hydraulic lines (1) connected to the latch at the top of the suspension assembly.

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6. Disconnect the air line (2) from the leveling valve on the suspension assembly.

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7. Remove the four mounting bolts (3, 4) securing the suspension assembly to the frame rail (driver's side).



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Cab Suspension Assembly Installation

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1. From the inner side of the frame rail, insert bolts into the two lower suspension mounting holes. These bolts will support the suspension assembly as it is placed in position in the next step. 2. Align the air suspension assembly with the two lower mounting bolts (4) and place it in position against the frame rail. 3. Install the bolts, washers and locknuts (3) in the two upper mounting holes to secure the suspension assembly to the frame. 4. Install the washers and locknuts on the lower mounting bolts (5). Tighten all four mounting bolts and nuts (3, 4) to 220 ft. lbs.

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5. Reconnect the hydraulic lines to the latch at the top of the assembly.

6. Reconnect the air line to the suspension leveling valve. 7. Secure all hydraulic lines away from moving parts. 8. Loosen the cab latch bar plate on the bottom of the cab deck. 9. Lower the cab slowly until the cab latch bar plate makes contact with the air suspension latch. Adjust the latch bar plate until it is centered in the latch and hand tighten the outer mounting nuts. DSC2441a

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10. Raise and support the cab. Then, tighten all four of the latch bar plate mounting nuts to 65 ft. lbs. 11. Make sure all lines are routed away from the rubber bumper contact area on the deck. Reroute and secure the lines if necessary. 12. Check the hydraulic lines for leaks.

NOTE After 100 hours of operation — Recheck fasteners for tightness. –

Air Ride Level Adjustment 1. Park the vehicle on firm level ground.


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2. Start and run the engine until the air system has a minimum of 100 psi of air pressure. 3. Shut the engine down. 4. Turn on (open) the air supply to the cab suspension by turning the “T-handle” valve on the bottom of the deck counterclockwise. 5. Remove the plastic clip (2) in the center of the plastic linkage rod connected to the control arm on the suspension assembly.

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6. Use tape to mark the linkage rod's current position (3).

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7. Adjust the linkage rod length as required to set proper ride height. Disengage the serrated lower end (4) of the rod from the serrated portion of its upper sleeve (1): DSC2443

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To raise ride level — Decrease the rod (4) length by placing the rod deeper into the upper sleeve (1). To lower ride level — Increase the rod length by reducing the insertion of the rod in the sleeve.

NOTE One inch of clearance is required between the stop bumpers on the air suspension assembly and the channel at the bottom of the cab deck for proper ride height.

7.2.2

Leveling Valve

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Valve Operation Check Check for proper operation of the leveling valve as follows: 1. While holding the cab entry handle in the “DOWN” position, count the time in seconds it takes for the air spring to raise the ride height. 2. If the noted time is: Within 2–10 seconds — Valve is OK. Under 2 seconds — Valve is damaged or filter is clogged. Over 10 seconds — Valve is damaged or filter is clogged.

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3. Replace the valve if the valve is damaged or the filter is clogged.



7.2.3

103

Shock Absorbers

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Shock Removal Replacement of the shock absorber is necessary if the cab ride becomes too bouncy under normal operating conditions. 1. Raise the cab and lock it in the full-tilt position. 2. Remove the nuts (1) from the 7/16-inch mounting bolts securing the shock absorber in the top and bottom mounting brackets at one side of the suspension assembly. 3. Remove the bolts and remove the shock absorber from the assembly. 4. Repeat the procedure to remove the second shock absorber at the opposite side of the assembly.

DSC2441b

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Shock Installation 1. Place the shock absorber in position between the mounting brackets at the side of the suspension assembly. 2. Install the 7/16-inch bolts and nuts to secure the shock absorber in the top and bottom mounting brackets. 3. Tighten the bolts and nuts to specification. 4. Repeat the procedure to install the second shock absorber at the opposite side of the assembly. 5. Unlock the cab tilt cylinder and lower the cab.


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7.2.4

Cab Latch Bar Plate

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Latch Bar Plate Adjustment The position of the cab latch bar plate is important. When properly positioned, it relieves stress on the cab/deck assembly. To properly position the cab latch bar plate, use this procedure. 1. Raise the cab and loosen all four nuts (1, 2) securing the cab latch bar plate to the bottom of the cab deck.

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2. With the plate loosened, lower the cab slowly ensuring the latch bar properly seats in the hold down latch (3) at the top of the suspension assembly. 3. Make adjustments (side-to-side, fore and aft) to center the bar in the latch.

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4. Tighten the two nuts (1) which are accessible at the outer end (long end) of the cab latch bar plate. 5. Raise the cab and tighten all four (1, 2) cab latch bar plate mounting nuts to specification. DSC2447

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6. Lower the cab and recheck the position of the bar in the latch. Readjust if necessary.



7.2.5

105

Cab Tilt Cylinder

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Cylinder Removal

WARN IN G 1. The hydraulic fluid in the system is under pressure. Care should be taken whenever the system is opened. Loosen fittings slightly and allow pressure to bleed off before removing hoses. 2. Safety glasses must be worn when working on the hydraulic system. 3. Use a safety strut to hold the cab in the raised position when the cylinder is removed. 1. Raise the cab using the cab tilt system.

NOTE If unable to raise the cab using the cab tilt system due to component failure, use the following steps to raise the cab. a. Release the cab latch by supplying hydraulic pressure to the latch mechanism. This can be done by engaging the cab tilt pump or, if the pump is not functioning, by attaching a small hand or electric pump to the hydraulic line for the latch.

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b. Secure an overhead hoist to the rear of the cab and raise the cab to its full-tilt position. 2. Place a safety bar between the bottom of the deck and the frame in a manner that prohibits the safety bar from slipping. 3. Using the cab tilt switch (or overhead hoist, if necessary), lower the cab until it rests on the safety bar and all pressure is removed from the cylinder. 4. Clean the area around the hose fitting on the pump with compressed air to reduce the possibility of contamination. 5. Position a catch can under the fitting to prevent spills. 6. Remove the hydraulic line from the cylinder.

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7. Plug or cap the hose end to prevent contamination; secure the line above the frame rail to prevent loss of hydraulic fluid.


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8. Remove the cab tilt cylinder from the vehicle as follows: 2000 year model and newer trucks — Remove the cotter key (1) from the support pin securing the lower end of the cylinder to the lower cylinder mounting bracket. While supporting the cylinder, remove the locknut and bolt (2) securing the upper end of the cylinder to the deck. 1999 year model and older trucks — Remove the cylinder support bolt from the lower end of the cylinder and remove the cylinder from the vehicle. –

Cylinder Installation 1. Prior to reassembly, inspect all fasteners, including support pins, bolts, nuts, etc., for damage and/or wear. Replace all parts that are damaged or show wear. 2. Support the cab tilt cylinder in place on the vehicle while installing the locknuts and bolts to attach the rear end of the cylinder to the mounting bracket on the frame rail. Tighten the locknuts and bolts to 200 ft. lbs. 3. Attach the front end of the cylinder to the mounting bracket on the frame as follows: 2000 year model and newer trucks — Install an adjustable collar around the cylinder and through the mounting bracket and cylinder eye. 1999 year model and older trucks — Install the bolt and locknut through the bracket and cylinder mounting eye and tighten to 200 ft. lbs. 4. Unplug the hydraulic hose end and connect it to the cylinder port. 5. Connect the electrical cables to the relay on the bottom of the cylinder. 6. Using the cab tilt switch, raise the cab and remove the safety bar. 7. Again, using the cab tilt switch, raise and lower the cab to bleed all air from the system; the system is self-bleeding. 8. Check all hoses and fittings for leaks. 9. Check the fluid level in the hydraulic tank; adjust as necessary.



7.2.6

107

Cab Tilt Pump and Motor

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Pump and Motor Removal

WARN IN G The hydraulic fluid in the system is under pressure. Care should be taken whenever the system is opened. Loosen fittings slightly and allow pressure to bleed off before removing hoses. Safety glasses must be worn when working on the hydraulic system. The cab tilt pump and motor are located on a bracket below the left main frame rail just rear of the engine with the cab tilt cylinder. 1. Disconnect the negative cable from the battery. 2. Locate and disconnect the two wires (1) at the solenoid under the pump motor.

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3. Locate and disconnect the battery cable (2) at the pump motor.

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4. Clean the area around the hydraulic hose fittings on the pump with compressed air to reduce the possibility of contamination.

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5. Position a catch can under the valve to prevent spills. 6. Disconnect and cap the two hydraulic lines (3) attached to the pump. 7. Remove the two mounting bolts, flatwashers and locknuts; remove the adjustable collar (4) from around the center of the pump and then remove the pump and motor assembly.

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Pump and Motor Installation 1. Place the cab tilt pump and motor assembly in position on the frame rail mounting bracket. Install the two mounting bolts, flatwashers and locknuts; tighten securely. Install the adjustable collar around the center of the pump. 2. Uncap the hose ends and connect the two hydraulic lines to the pump. 3. Connect the two wires to the solenoid under the pump motor. 4. Connect the battery cable to the pump motor. 5. Check the fluid level in the hydraulic tank. 6. Connect the negative cables from the batteries. 7. Using the cab tilt switch, raise and lower the cab to bleed all air from the system; the system is self-bleeding. 8. Check all hoses and fittings for leaks.


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9. Check the fluid level in the hydraulic tank; adjust as necessary. –

Relief Pressure Adjustment (2001 and Newer Trucks) 1. Raise the cab to the full-tilt position. Check to ensure that the safety latch has engaged. 2. Slightly loosen the fitting at the cab tilt cylinder to relieve system pressure. 3. Install a “T” fitting in the supply line from the pump to the cab latch and connect a hydraulic pressure gauge to the fitting. 4. Locate the adjusting screw on the pressure relief valve body. The valve can be found between the inlet port on the pump and the motor. 5. While holding the adjusting screw with an Allen wrench, loosen the jam nut. 6. With the cab raised all the way up, hold the tilt control switch in the “UP” position. Note the reading on the hydraulic pressure gauge. 7. Turn the adjusting screw in or out as required to reach the specified relief pressure. 8. Using an Allen wrench, hold the adjusting screw in place and tighten the jam nut securely. 9. Disconnect the hydraulic gauge and remove the “T” fitting from the supply line; reconnect the supply line. 10. Check the supply line hose and fittings for leaks. 11. Lower the cab.

7.2.7

Cab Pivot Bushing

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Pivot Bushing Removal

WARN IN G Make sure all safety devices are in place while the cab is in the raised position.



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1. Raise the cab to the full-tilt position and make sure the safety arm is in place.

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2. Remove the SNAPTRAC® bolts from the left front corner of the frame cross member and from the bottom of the cab channel. Allow the SNAPTRAC to hang loose. 3. Remove the p-clamp that secures the frame and engine harnesses at the left front corner of the front cross member. 4. Remove the heater hose p-clamp at the front right top of the frame cross member. 5. Remove the spacer bracket (1) at the front left cab pivot pin.

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6. Remove the cab pivot retainers (2) from the pivot pins at the left and right sides of the cab.

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7. Remove both front headlight buckets. 8. Place 4x4x6-inch blocks on the top of the frame rails to support the cab, then lower the cab onto the blocks. This will help stabilize the cab while removing the cab bushings (4).

NOTE The blocks should be of sufficient thickness to fill the space between the frame rails, cab deck channels and pivot brackets. This will support the cab in the ride level position when the pivot pins are removed.

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9. Stabilize the right rear of the cab deck by chaining it down.

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10. Using a drift, drive the front cab pivot pins (4) out. 11. Using the cab tilt switch, operate the switch in the “UP” position until the cab deck has cleared the cab tilt bushings in the frame.

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12. Support the front of the cab deck by placing additional blocks between the deck and frame.

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13. Using a drift, drive the old bushings out of the left and right cab pivot blocks.

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110


Pivot Bushing Installation 1. Install new bushings into the cab pivot blocks.

NOTE The bushings are a light press-fit. 2. Remove the additional blocks placed in position to support the cab in the raised position after the pivot pins were removed. 3. Using the cab tilt switch, lower the cab deck down to the desired height on the original blocks placed in position to support the cab. Install the cab tilt pins. 4. Install the cab pivot retainer (2) at each pivot pin. 5. Install the spacer bracket (1) at the front left cab pivot pin. 6. Install both front headlight buckets. 7. Install the p-clamp that secures the frame and engine harnesses at the left front corner of the front cross member. 8. Install the SNAPTRAC bolts at the front left corner of the frame cross member and from the bottom of the cab channel. 9. Lower the cab and check for hose routing issues.



7.2.8

111

Rear Door

page –

Rear Door Adjustment Use the following procedures to maintain smooth operation of the rear door.

9/16" (.563)

1. Measure the gap between the closed door and the upper corner of the door frame.

1

2. If the measurement is not 9/16 inch (0.563 inch), loosen the capscrews (1) that hold the rollers.

DSC2483

3. Move the door in the appropriate direction to reach 9/16 inch, then tighten the capscrews to specification.

4. Measure the gap between the closed door and the lower corners of the door frame. 5. If the measurement is not 9/16 inch (0.563 inch), adjust the lower guide and/or rollers as follows: a. Check the rollers with the door in both the open and closed positions and determine where the rollers are closest to the guide. DSC2480

9/16" (.563)

b. At the closest position, adjust the rollers so that they are snug against the lower guide. Adjust the outer rollers first and then the center rollers. c. Once the rollers are adjusted to the lower guide, close the door and adjust the lower roller mounting plate to a gap of 9/16 inch.


112

Notes


8.1 Standard Vehicle Data – 8 Specifications

113

8 Specifications

mm mm mm mm mm mm

8.1

Standard Vehicle Data

Ottawa Series Terminal Tractor

page –

Standard features, dimensions and performance specifications are presented below for three typical chassis configurations. Optional equipment items are available including ABS braking systems and GCW ratings up to 125,000 pounds depending on the engine, transmission and axle combinations. Chassis Model and Configuration

Ottawa 4x2

Ottawa 4x2

Ottawa 6x4

Off-Highway

DOT/EPA Certified

DOT/EPA Certified

Cummins QSB6.7

Cummins ISB07

Cummins ISB07

Peak power (HP @ rpm)

160 at 2200

200 at 2300

200 at 2300

Torque (ft. lbs. @ rpm)

540 at 1500

520 at 1600

520 at 1600

Allison 3000RDS

Allison 3000RDS

Allison 3000RDS

Gearing

3 Forward, 1 Reverse

4 Forward,1 Reverse

4 Forward,1 Reverse

Propeller shaft

Spicer 1710

Spicer 1710

Spicer 1710

Meritor FF961

Meritor FF961

Meritor FF961

Meritor RS-23-186

Meritor RS-24-160

Meritor RT-40-145

Wheel ends: type, size (ins.)

Air

Air with ABS

Air with ABS

Front – type, size (ins.)

S-cam, 16.5x5

S-cam, 16.5x5

S-cam, 16.5x5

Rear – type, size (ins.)

S-cam, 16.5x7

S-cam, 16.5x7

S-cam, 16.5x7

Slack adjusters

Manual

Automatic

Automatic

Air compressor

Wabco, 15.2 cfm

Wabco, 15.2 cfm

Wabco, 15.2 cfm

3,582 (2 tanks)

5,688 (3 tanks)

5,688 (3 tanks)

11R 22.5, 14PR

11R 22.5, 14PR

11R 22.5, 14PR

Front

12,000

12,000

12,000

Rear

23,000

24,000

40,000

96,000

80,000

80,000

Wheelbase (ins.)

110

110

146

Length overall (ins.)

181

181

244

Width overall (ins.)

97

97

97

Application (certification) Engine (standard)

Transmission (standard)

Axle, front Axle(s), rear Brake system

Air reservoirs (cu. ins.) Tires GAWR (lbs.)

GCWR (lbs.)


114

8.1 Standard Vehicle Data – 8 Specifications

Chassis Model and Configuration Turning radius (ft.) Fifth-wheel boom lift capacity (lbs.) Fifth wheel Chassis weight (lbs.)

Ottawa 4x2

Ottawa 4x2

Ottawa 6x4

17

17

19.85

60,000

60,000

60,000

FW 3500

FW 3500

FW 3500

14,500

14,500

18,000


8.2 Hydraulic System – 8 Specifications

8.2 page –

115

Hydraulic System

Ottawa Series 4x2 and 6x4 The hydraulic system includes three sub-systems. •

Fifth-wheel boom

•

Power steering

•

Cab tilt

All three draw and use fluid from a common 16-gallon reservoir. Specifications for the individual sub-systems follow. Boom System Components Boom drift down (maximum, 5-inch cylinder) Hydraulic fluid Pump flow (standard system)

Specification 3 inches per hour Dexron® III 10 gpm at 1200 rpm

System capacity: Tank only System System relief pressure

Power Steering System Components Pump flow (minimum) Pump relief setting

Cab Tilt System Components Pump flow (minimum) Pump relief setting


16 gallons 21 gallons (approximate) 2000 psi

Specification 4 gpm at 1200 rpm 2100 psi

Specification 0.3 gpm at 1200 rpm 3200 psi

116

8.3 Fluids, Lubricants and Sealants – 8 Specifications

8.3

Fluids, Lubricants and Sealants

page –

Ottawa Series 4x2 and 6x4 Following are the specified fluids, lubricants and sealants by component. These are to be used in accordance with the recommended maintenance schedule. Component

Sealant or Lubricant

Axle, rear

EP 85-140 (Also, refer to axle manufacturer’s specifications.)

Cab: Cab pivot bearings

Lubriplate® or equivalent (semi-fluid grease having extreme pressure properties and containing zinc oxide)

Cab tilt release mechanism Door striker bolts Seat adjuster slides Cab: Door hinges

Silicone spray

Rear door rollers Chassis: Boom pivot (at frame) Brake cam pivots Brake slack adjusters Fifth-wheel pivot pins Fifth-wheel top plate Fifth-wheel jaws

Lithium Grease #1

Front axle king pins Hydraulic cylinder bearings Otto-Ride pivots Propeller shaft splines and universal joints Speedometer adapter Spring shackle pins Engine: Oil Coolant, anti-freeze

SAE 15W-40 50/50 Ethylene-Glycol/Water (Also, refer to engine manufacturer’s specifications.)

Hydraulic system fluid Steering fluid (power steering)

Dexron® III Dexron® III (from hydraulic system)


8.3 Fluids, Lubricants and Sealants – 8 Specifications

Component

117

Sealant or Lubricant

Steering linkage (slip joint, knuckles, tie rod and drag link ends) Transmission fluid/lubricant (automatic)

Lithium grease (warm weather) NLGI 0 lubricant (cold weather) Transynd TES-295 Approved (Also, refer to transmission manufacturer’s specifications.)

Wheel bearings, front axle: Grease lubricated

NLGI 1 or 2

Oil lubricated

EPA 85-140 (Also, refer to axle manufacturer’s specifications.)


118

8.4 Fastener Torque Values – 8 Specifications

8.4

Fastener Torque Values

page –

Ottawa Series 4x2 and 6x4 Following are the specified torque values required for scheduled maintenance operations and typical repair and/or adjustment procedures covered in this manual. Component

Specified Torque Value

Axle mounting: Front axle clamp plate bolts

210 ft. lbs.

Rear axle clamp plate bolts

Bolt head 600 ft. lbs., Nut 400 ft. lbs.

Rear axle torque link bolts

380 ft. lbs.

Cab latch mounting bolts

65 ft. lbs.

Cab latch bar plate mounting bolts

65 ft. lbs.

Cab pivot pin retainer screws

35 ft. lbs.

Cab rear door roller capscrews

75 in. lbs.

Cab suspension: Assembly mounting bolts

220 ft. lbs.

Shock absorber mounting bolts

100 ft. lbs.

Cab tilt cylinder mounting bolts

200 ft. lbs.

Cab tilt pump mounting bolts

35 ft. lbs.

Cab tilt pump relief valve adjusting screw jam nut

80 in. lbs.

Boom cylinder mounting: Upper mount bolts

55 ft. lbs.

Lower mount bolts

55 ft. lbs.

Lower mount cross-bar locknuts

600 ft. lbs.

Boom pivot cross-bar locknuts

600 ft. lbs.

Boom pump mounting bolts

55 ft. lbs.

Boom pump relief valve adjusting screw jam nut

15 ft. lbs.

Spring pin bolts, fixed/shackle (front axle)

150 ft. lbs.

Steering gear mounting bolts

350 ft. lbs.

Wheel lug nuts

450-500 ft. lbs.


9.1 Air System Circuits – 9 Schematics

mm mm mm mm mm mm

9 Schematics 9.1 9.1.1

page –

119

Air System Circuits Air Brakes

Components ABS Electronic Control Unit ABS Modulator Valve Air Compressor Air Dryer (Optional) Air Pressure Governor Air Reservoirs (Storage Tanks) Brake Chambers Check Valves Foot Pedal (Treadle) Valve Interaxle Lockout (6x4 only, ABS) Pressure Relief Valves Proportioning Relay Valve Quick Release Valves Slack Adjusters Stoplight Switch Tractor Parking Brake Control Valve Tractor Protection Valves Trailer Air Supply Control Valve Two-Way Check and Quick Release Valves Vehicles intended for road use conform to Federal Motor Vehicle Safety Standard (FMVSS) 121. This standard specifies test requirements for air brake systems. Semi-trailer tractors must be equipped with an anti-lock brake system (ABS) and meet stopping distance requirements under normal and emergency conditions. ABS is optional on tractors that do not use the roads. Vehicles intended for road use also conform to applicable Canadian Motor Vehicle Safety Standards (CMVSS).

page –


120


Air Brake System with ABS The Ottawa ABS has three air reservoirs (storage tanks); primary, front and rear. The primary acts as the supply tank to both front and rear service tanks. The instrument panel displays a pressure gauge for each service tank.


OTT0043

122

–


Air Brake System without ABS The air brake system without ABS has two air storage tanks, supply and service. There is one pressure gauge on the instrument panel.


OTT0044

124


9.1.2

Cab Seating

Air Lines — Driver's Seat

page –

AIR LINES DRIVER’S SEAT BRAKE TREADLE

NE

AR

SI

DE

AIR SEAT TO BRAKE SYSTEM CAB FLOOR BULKHEAD

PLUGS

DELIVERY SUPPLY TO SERVICE RESERVOIR

NEAR SIDE

OTT0045

TO MANIFOLD 8 PORT

Air Lines — Driver's Seat Components Air Control Valve Air Spring Air Reservoir The adjustable driver's seat cushion rides on an air bag. A locking mechanism allows the driver to stop fore and aft chugging if desired. Seating comfort controls are mounted on each side below and in back of the seat cushion.



9.1.3

125

Cab Suspension

Air Lines — Cab Suspension

page –

AIR LINES CAB SUSPENSION

BRAKE TREADLE

NE

AR

SI

DE TO BRAKE SYSTEM

AIR RIDE SUSPENSION

PLUGS

DELIVERY SUPPLY

TO DRIVER’S SEAT

HEIGHT CONTROL VALUE

CAB SUSPENSION AIRRIDE

TO SERVICE RESERVOIR TO MANIFOLD 8 PORT

NEAR SIDE

Air Lines — Cab Suspension Components Air Spring Height Control Valve Latch Shock Absorbers Ride level is adjustable and automatically maintained. Two shock absorbers react with the air spring to maintain a soft, smooth ride. A rubber bumper prevents the cab from striking the rails.


OTT0046

NEEDLE VALUE

126


9.1.4

Fifth-Wheel Coupling

Air Lines — Fifth-Wheel Latch

page –

5TH WHEEL UNLATCH

AIR LINES FIFTH WHEEL

3/8 BK 5TH WHEEL AND BOOM 5TH WHEEL UNLATCH

3/8 YW

TO BRAKE TANK

MANIFOLD, 8 PORT

3/8 YW TO TRACTOR PARK (YELLOW) PLUGS TO TRACTOR PARK (RED)

3/8 YW

PLUG

BRAKE TREADLE

NE

3/8 BK

SI

DE

TO BRAKE SYSTEM

RS FA

PLUGS

IDE


OTT0049

AR

Air Lines — Fifth-Wheel Latch Components Air Control Valve Air Cylinder Air Reservoir Pressing the control valve button on the instrument panel opens the latch. The button is spring-loaded and normally closed. Once opened, the latch remains open until closed by a trailer king pin.


9.2 Hydraulic System Circuits – 9 Schematics

9.2

127

Hydraulic System Circuits

Hydraulic Systems

page –

One electric motor with integral pump and one hydraulic fluid reservoir are shared by the fifth-wheel boom, cab tilt and power steering systems. Each system operates independently. The motor is mounted on the transmission housing. All fluid passes through a filter mounted beside the reservoir.

9.2.1

Cab Tilt

Hydraulic Lines — Cab Tilt

page –

CAB TILT HYDRAULIC SYSTEM HYDRAULIC CAB TILT CYLINDER

HYDRAULIC PUMP CAB UNLOCK ADAPTOR

OTT0048

HYDRAULIC RESERVOIR TANK

Hydraulic Lines — Cab Tilt System Components Control Switch Hydraulic Cylinder Lanyard Safety Prop Solenoid For tilting the cab, the motor is controlled by a switch on the rail. A lanyard near the switch allows the operator to unlatch the safety prop prior to up or down movement.


128


9.2.2

Fifth-Wheel Boom

Hydraulic Lines — Fifth-Wheel Boom

page –

5TH WHEEL UNLATCH

AIR LINES FIFTH WHEEL

3/8 BK 5TH WHEEL AND BOOM 5TH WHEEL UNLATCH

3/8 YW

TO BRAKE TANK

MANIFOLD, 8 PORT

3/8 YW TO TRACTOR PARK (YELLOW) PLUGS TO TRACTOR PARK (RED)

3/8 YW

PLUG

BRAKE TREADLE

NE

3/8 BK

SI

DE

TO BRAKE SYSTEM

RS FA

PLUGS

IDE


OTT0049

AR

Hydraulic Lines — Fifth-Wheel Boom Components Boom Control Valve Hydraulic Cylinders Hydraulic Relief Valve Although engine speed controls the speed of the double-acting cylinders, restrictors slow the downward motion.



9.2.3

129

Power Steering

Hydraulic Lines — Power Steering

page –

POWER STEERING HYDRAULIC SYSTEM

HYDRAULIC PUMP

STEERING GEAR

OTT0050

HYDRAULIC TANK

Hydraulic Lines — Power Steering System Components Integral Steering Gear The power steering system shares the hydraulic fluid reservoir with the cab tilt and boom lift systems.


130

9.3 Electrical System Circuits – 9 Schematics

9.3

Electrical System Circuits

9.3.1

Starting and Charging

Starting and Charging Circuit ELECTRONIC ENGINE BULKHEAD CONNECTOR

IG2000 YW

STARTING AND CHARGING CIRCUIT

IGNITION

NEGATIVE PASS-THRU STUD

GA2001 WE IG1001 YW

85 87

86 30

POSITIVE 11 PASS-THRU 12 21 STUD 8 BA2000 RD 19

PR1

CAB ACC FUSE GAUGE GAUGE 10 A

1

IG2006 BN/RD GA2003 OE/WE

GA2003 OE/WE RD (ALTERNATOR-TO-STARTER)

R ALTERNATOR

IGNITION SWITCH B

10 A

ST2001 PK/WE

85 87 87A

1

GD1001 WE ST2002 PK/WE

RD

RD

I

RD (BATTERY-TO-STARTER) IGNITION SWITCH CONNECTOR

C D B

IG2000 YW GD1001 WE

NEUTRAL START 86 30

BATTERIES

BK

S

ST2000 PK IG2000 YW IGN SW

ST2000 PK

BA2000 RD

TR-141 TN

CAB ACC FUSE IGNITION SWITCH

IG1000 RD/WE A

ST2001 PK/WE ST2002 PK/WE

GD2001 WE

A

MID FRAME CROSSMEMBER CONNECTOR

G U S L C F X V N D M B T P J W K R H A E

#1 START 85 CUTOUT 86 87 30 87A R14 #2 START 85 CUTOUT 86 87 30 87A R14


IG2006 BN/RD GA2003 OE/WE

RD/WE RD

GA2003 OE/WE

GA2003 OE/WE

OIL PRESSURE SWITCH (HOURMETER)

C D A B

BA2000 RD

GD2001 WE

IG2000 YW

POSITIVE PASS-THRU STUD

F L M H E J G C D K A B

GD1001 WE ST2002 PK/WE

MD TRANS V HARNESS CAB CONNECTOR

RD (BATTERY-TO STARTER)

RD/WE (START SOL.-TO STARTER)

STARTER W/SOLENOID

RD (STARTER-TO START SOL.)

GROUND

START SOL.

GD1001

TR-141 TN – NEUTRAL START (+)

CHASSIS BULKHEAD CONNECTOR

TRANSMISSION CASE GROUND

ST2000 PK

R6

ST2002 PK/WE

OTT0075

ST2002 PK/WE

GEN-4 3000 TRANSMISSION ECU (TCM)

29 65 5 24 64 50 13 4 45 32 72 46 18 41 30 69 9 70 10 63 43 2 23 62 42 1 61 21 22 79 17 57 3 73 53 14 38 34 25 7 28 8 49 48 68 26 6 27 67 66 47 12 44 56 35 58 75 16 54 76 77 11 55 78 74 71 36 52 33 51 31 15 37 19 39 59 40 60 20 80

GA2003 OE/WE

GEN-4 ECU CONNECTOR

6 5 17 26 16 28 15 25 14 13 22 9 10 7 4 3 2 1 29 20 18 23 27 24

IG2006 BN/RD

page –

Starting and Charging Circuit



131

Components Alternator Batteries Circuit Breaker — Ignition Switch (Cab Accessory Fuse Panel) Fuse — Gauge (Cab Accessory Fuse Panel) Ignition Relay Ignition Switch Neutral Start Relay Oil Pressure (Hourmeter) Switch Start Cutout #1 Relay Start Cutout #2 Relay Start Solenoid Starter Motor with Solenoid

9.3.2 page –

Cab Accessory Components

Wire Color Codes BE = Blue BK = Black BN = Brown GN = Green OE = Orange PE = Purple PK = Pink RD = Red TN = Tan WE = White YW = Yellow

–


132


Anti-lock Braking System (ABS) For information on the anti-lock braking system, refer to the vendor's service manual.

Heater and Air Conditioning

–

HEATER/AIR CONDITIONING CIRCUIT

HC1000 RD/WE

AIR CONDITIONER SWITCH CONNECTOR

ELECTRONIC ENGINE BULKHEAD CONNECTOR

HTR-LOW GY HTR-MED BK HTR-HI OE

HC1000 RD/WE

HC1000 RD/WE HC2001 YW/RD HC2001 YW/RD

HC1000 RD/WE

HC2001 YW/RD HC2003 YW/BK HC2002 HC2003

HC2001 YW/RD HC2002 YW/BK HTR-LOW GY HTR-MED BK HTR-HI OE

B A C D F E

A/C LOW PRESSURE SWITCH & COLD CONTROL CONNECTOR

A/C LOW PRESSURE SWITCH & COLD CONTROL CONNECTOR

HC2001 YW/RD

COLD CONTROL

HEATER & A/C

HC1000 RD/WE

B

BK A

CAB ACC FUSE HVAC 30 A


A/C HIGH PRESSURE SWITCH

IGNITION SWITCH CONNECTOR OPTIONAL A/C COMPRESSOR

3

ACC #1

AC1000 BN

A/C LOW PRESSURE SWITCH

I

A C D B

HVAC

S

AC2000 BN

GD2001 WE

85 87 87A

A B

A B

FAN MOTOR NEGATIVE PASS-THRU STUD

HC2001 YW/RD HC2003 YW/BK

A/C SWITCH

E L H D J K F G M A B C

CAB CONTROL PANEL CONNECTOR

GD2001 WE HC1000 RD/WE

A B

HC1000 RD/WE HC2001 YW/RD FC2000 BK

HC1000 RD/WE HC1000 RD/WE

GD2001 WE

HC2001 YW/RD HC2001 FC2000

11 12 21 8 19 6 5 17 26 16 28 15 25 14 13 22 9 10 7 4 3 2 1 29 20 18 23 27 24

86 30 R2

BA2001 RD

HC2003 YW/BK

OPTIONAL A/C HIGH PRESSURE


Heating and Air Conditioning Circuits Components Accessory Relay #1 Air Conditioner Switch Cab Fan (Optional) Cold Control (AC Optional) HVAC Fan Motor Fan Switch Fuse — HVAC (Cab Accessory Fuse Panel) Ignition Switch Air conditioning is optional equipment.


OTT0036

OPTIONAL CAB FAN

HC1000

FAN SW L OFF M H C


133

Horn

–

HORN CIRCUIT HORN

HN2000 GN/BK

HN2000 GN/BK

CAB ACC FUSE HORN HORN 10 A

1

HORN 85 87 87A

86 30


HN2000 GN/BK

BA2002 RD


REMOVE POSITIVE STUD

HN1000 GN

R7

HN2000 GN/BK HN2001 GN/WE

GD2000 WE

NEGATIVE PASS-THRU STUD OTT0037

HORN

Horn Circuit Components Circuit Breaker — Horn (Cab Accessory Fuse Panel) Horn Horn Button Horn Relay The horn operates independently of the ignition switch. –


134


Mirrors Heated (Optional) CAB BULKHEAD CONNECTOR

HEATED MIRROR CIRCUIT MIRROR CONNECTOR LEFT SIDE A B

MR1000 RD GD2000 WE MIRROR CONNECTOR LEFT SIDE MR1000 RD A GD2000 WE B

MIRROR HEAT CONVEX RIGHT SIDE

MR1000 RD GD2000 WE

MR1001 OE GD2000 WE

MR1000 RD GD2000 WE

BUS BAR

CONVEX MIRROR CONNECTOR LEFT

AC1001 BN

A B

MR1000 RD GD2000 WE

MR1000 RD GD2000 WE

MR1000 RD GD2000 WE

MR1000 RD GD2000 WE

A B


GD2000 WE

MR1001 OE GD2000 WE MR1000 RD

15 A 4

MIRROR HEAT CONVEX RIGHT SIDE MR1000 RD GD2000 WE

A B

CONVEX MIRROR CONNECTOR RIGHT

GD2000 WE

MR1001 OE

A B

MIRROR CONNECTOR RIGHT SIDE

MIRROR DASH HARNESS CONNECTOR

CAB ACC FUSE MIRRORS MIRRORS

MIRROR HEAT RIGHT SIDE

MIRROR CONNECTOR RIGHT SIDE

MIRROR HEAT SWITCH A B C

4

MR1001 OE GD2000 WE MR1000 RD

5 1

ACC #2 AC1001 BN

85 87

86 30 PR2


OTT0078

MIRROR HEAT RIGHT SIDE

C G M N W F R B E J L K T H X D V U A P S

Heated Mirror Circuit Components Circuit Breaker — Optional Accessory Heater Switch Left-Hand Mirror Heater Right-Hand Mirror Heater An indicator lamp illuminates when the mirror heater is active. The ignition switch must be On to use the mirror heater.



135

Heated and Motorized (Optional)

CAB BULKHEAD CONNECTOR

ACC #2 85

86

87

30

GD2000 WE

LH MIRROR

MIRROR CONNECTOR LEFT HAND

BUS BAR

RD BK

CAB ACC FUSE MIRRORS MIRRORS

A B

MR1000 RD GD2000 WE

MR1001 OE

MR1000 RD MR1003 RD/WE MR1004 RD/WE MR1003 RD/WE MR1004 RD/WE

HEATER

GD2000 WE MR1000 RD

AC1001 BN

PR2


C G M N W F R B E J L K T X H D V U A P S


GD2000 WE

RH MIRROR CCW MR1000 RD MR1003 RD/WE MR1004 RD/WE

A B C D

RD BK WE GN

CW

HEATER

MIRROR CONNECTOR RIGHT HAND

F

D E

MOTO MIRROR DASH HARNESS CONNECTOR

A B C

15 A 4 MR1004 RD/WE MIRROR REMOTE SWITCH RIGHT HAND

MR1000 RD

HEATED MOTO-MIRROR CIRCUIT

6 5

2

MR1008 OE/WE

MIRROR HEAT SWITCH

MR1002 BK/WE

GD2000 WE MR1003 RD/WE MR1001 OE

OTT0077

3

Heated and Motorized Mirror Circuit Components Circuit Breaker — Optional Accessory Heater Switch Left-Hand Mirror Heater Left-Hand Mirror Motor Left-Hand Motor Switch Right-Hand Mirror Heater Right-Hand Mirror Motor Right-Hand Motor Switch An indicator lamp illuminates when the mirror heater is active. The ignition switch must be On to use the mirror heater and motor.


136


Radio (Optional)

–

IGNITION SWITCH B

RADIO CIRCUIT OVERHEAD/UNDER DASH

10 A AC1001 BN

CAB ACC RADIO FUSE RADIO ACCY

B

D

IGNITION SWITCH CONNECTOR

1

RD2002 BN/RD

ACC #1 85 87 87A

86

AC2000 BN

30

BA2001 RD


R2

RADIO UNDER DASH

RD2002 BN/RD

3

B C

GD2006 WE RD2002 BN/RD RD1003 RD

RADIO UPPER CAB CONNECTOR GD2006 WE RD2002 BN/RD RD1003 RD

A B

GD2006 WE RD2002 BN/RD

RADIO UNDER DASH CONNECTOR

A B C

REMOTE POSITIVE STUD

GD2006 WE RD2002 BN/RD RD1003 RD


GD2006

RD2002 BN/RD RD1003 RD

BA2004 RD BUS BAR

A

RADIO OVERHEAD

RD2002 BN/RD

TERMINAL FOR RADIO CONNECTOR

GD2006 WE

TERMINAL FOR CB RADIO CONNECTOR

CAB ACC RADIO BATTERY FUSE RADIO BATT 5 A

Radio Circuit Overhead/Under Dash


2

OTT0040

5 A

IG1000 RD/WE

I

RD2002 BN/RD

BUS BAR

AC1001 BN

A

CAB ACC IGNITION SWITCH FUSE IGN SW

BA2000 RD

C


S

IG1000 RD/WE AC2000 BN

A


137

IGNITION SWITCH B

RADIO CIRCUIT HOT WIRE

10 A

1

87A

86

AC2000 BN

30

BA2001 RD

R2

BUS BAR

AC1001 BN

RD2002 BN/RD GD2006 WE

B A

B

CAB ACC RADIO FUSE RADIO ACCY 10 A

TERMINAL FOR CB RADIO CONNECTOR


3

RD2002 BN/RD GD2006 WE RADIO UPPER CAB CONNECTOR


Radio Circuit — Hot Wire Components Accessory Relay #1 Circuit Breaker — Radio Battery (Cab Accessory Fuse Panel) Fuse — Ignition Switch (Cab Accessory Fuse Panel) Fuse — Radio (Cab Accessory Fuse Panel) Ignition Switch The ignition switch must be On to use the radio.


OTT0088

AC1001 BN

D

A

IG1000 RD/WE

ACC #1 85 87

I

AC2000 BN

BA2000 RD

C


CAB ACC IGNITION SWITCH FUSE IGN SW

IGNITION SWITCH CONNECTOR

S

IG1000 RD/WE AC2000 BN

A

138


Windshield Washer (Optional)

–

WINDSHIELD WIPER SW

WINDSHIELD WASHER CIRCUIT

L

OPTIONAL WINDSHIELD WASHER

H W B

CAB ACC FUSE WIPER/WASHER WIPER/WASH 15 A

WW2003 GN

4

ACC #1 85 87 87A

86 30 R2

BA2001 RD


A B

WW2003 GN

WASHER CONNECTOR

GD1001 WE


OTT0041

BUS BAR

AC1000 BN


WW2003 GN GD1001 WE

C B WW1000 PE/RD A E WW2003 GN D F

WIPER SWITCH CONNECTOR


WW2003 A GD1001 B

WW1000 PE/RD WW2003 GN

P

Windshield Washer Circuit Components Accessory Relay #1 Circuit Breaker — Wiper/Washer (Cab Accessory Fuse Panel) Windshield Washer Motor Windshield Wiper Switch The ignition switch must be On to use the windshield washer.



139

Windshield Wiper

–

WINDSHIELD WIPER CIRCUIT

WINDSHIELD WIPER SW H W

L

B P

ACC #1

GRD

WIPER MOTOR CONNECTOR F

GD2001 WE WW2000 PE WW1000 PE/RD WW2002 PE/WE WW2001 PE/BK

E D C B A

HI

AC1000 BN

F

D

E

CAB ACC FUSE WIPER/WASHER WIPER/WASH 15 A 4

Windshield Wiper Circuit Components Accessory Relay #1 Circuit Breaker — Wiper/Washer (Cab Accessory Fuse Panel) Windshield Wiper Motor Windshield Wiper Switch The ignition switch must be On to use the windshield wiper. Maintenance manual Ottawa 4x2, 6x4

OTT0042

LO

BN BE BK RD GN

WW1000 PE/RD

PARK

BUS BAR

ELEC. WIPER

AC1000 BN

BATT

WW2002 PE/WE

WIPER MOTOR

C


A

WIPER SWITCH CONNECTOR

WW2001 PE/BK WW2000 PE WW1000 PE/RD

R2

B


BA2001 RD

30

WW2001 PE/BK WW2000 PE WW1000 PE/RD

87 87A

WW2002 PE/WE

86

85

140


9.3.3

Cab Instrumentation

Air Pressure Gauge Lighting

page –

Components WITH OPTIONAL DIMMER SWITCH

STANDARD

Gauge

AIR GAUGE LIGHTING CIRCUIT

S9 PANEL LTS DIMMER

Gauge (Second Service Tank) Gauge Lamp

S1 HEADLAMP SWITCH

S1 HEADLAMP SWITCH

Gauge Lamp (Second Service Tank) Headlight Switch

AIR PRESS

PL2002

L

F E A H B C D G J K L M

ENGINE GAUGE & WARNING PANEL CONNECTOR

C G PL2002 BE/RD M N W F R B E J L K T H X D V U A P S

PL2002

B C A

Vehicles equipped with ABS have two service tanks and a pressure gauge for each one.

OPT AIR PRESS

G

L

G

PL2002 GD2002 BRAKE CONTROLS PANEL CONNECTOR

GD2002 WE


NEGATIVE PASS–THRU STUD

OTT0073

PL2002


Air Pressure Gauge Lighting Circuit



141

Ammeter (Optional)

–

WITH OPTIONAL DIMMER SWITCH

AMMETER CIRCUIT

STANDARD

S9 PANEL LTS DIMMER

S1 HEADLAMP SWITCH

S1 HEADLAMP SWITCH

OPTIONS BULKHEAD CONNECTOR

GA7 7 8 9 3 12 11 10 1 2 6 5 4

PL2002

PL2002

AMMETER

L

I

G

S

GA2004 GY GA2005 GY/RD

A B



AMMETER DASH CONNECTOR PL2002 BE/RD GD2000 WE

PL2002 BE/RD GD2000 WE

A B

LIGHT BAR CONNECTOR JUMPER

LIGHT BAR LIGHT BAR CONNECTOR FOR OPTION SWITCHED

AMMETER CHASSIS CONNECTOR

GA2005 GY/RD GA2004 GY

B A

GA2005 GY/RD GA2004 GY

RD

RD AMMETER SHUNT STARTER W/SOLENOID

R ALTERNATOR

GROUND

BATTERIES

RD (BATTERY-TO-STARTER)

BK


Ammeter Gauge Circuit


OTT0051


142


Components Alternator Ammeter Ammeter Lamp Ammeter Shunt Batteries Headlight Switch Light Bar Panel Dimmer Switch (Optional) Starter with Solenoid –

Engine Coolant Temperature Gauge

ENGINE COOLANT TEMPERATURE GAUGE CIRCUIT WITH OPTIONAL DIMMER SWITCH

STANDARD GA4

S9 PANEL LTS DIMMER

WATER L

PL2002 BE/RD

I

G

S

IG2006 BN/RD GD2000

WE

86 30 PR1

IG1001 YW


1

GA2002 GN/BK


Engine Coolant Temperature Gauge Circuit


WATER TEMPERATURE SENDER

OTT0052

GA2002 GN/BK

IGNITION 85 87

C

GA2002 GN/BK D

PL2002 BE/RD

ENGINE GAUGE & WARNING PANEL CONNECTOR 11 12 21 8 19 6 5 17 26 16 28 15 25 GA2002 GN/BK 14 13 22 9 10 7 4 3 2 1 29 20 18 23 NEGATIVE 27 PASS–THRU 24 STUD

G J K L M

IG2006 BN/RD GD2000 WE

PL2002

PL2002

F E

S1 HEADLAMP SWITCH

IG2006 BN/RD A GD2000 WE H GD2000 WE B

GA2002 GN/BK S1 HEADLAMP SWITCH


143

Components Coolant Temperature Gauge Fuse — Gauge (Cab Accessory Fuse Panel) Gauge Gauge Lamp Headlight Switch Ignition Relay Panel Dimmer Switch (Optional) Sender (Water Temperature — Variable Resistance) The engine coolant temperature gauge reads in degrees Fahrenheit (°F). –

Engine Hourmeter

ENGINE HOURMETER HOUR METER GD2000

HOURS 3

1


WE

2

S


1

IGNITION 85

86

87 30 PR1

IG1001

A

C

B

G

M

J

F

K

D

L

11 12 CAB CONTROLS PANEL CONNECTOR 21 8 19 6 5 17 26 16 28 15 GA2003 OE/WE 25 14 13 22 9 10 7 4 3 2 1 29 20 CAB ACC 18 FUSE GAUGE 23 GAUGE 27 24 10 A 1

IG2006 BN/RD OIL PRESSURE SWITCH (HOURMETER)

OTT0071

10 A

IG1000 RD/WE

E

BA2000

IG1000 RD/WE

GA2003 OE/WE POSITIVE PASS–THRU STUD

CAB ACC CB IGNITION SWITCH IGN SW RD

H

GD2000 GA2003 IG1000

YW

Engine Hourmeter Circuit


144


Components Circuit Breaker — Ignition Switch (Cab Accessory Fuse Panel) Fuse — Gauge (Cab Accessory Fuse Panel) Hourmeter Ignition Relay Oil Pressure (Hourmeter) Switch The hourmeter operates when engine oil pressure reaches the set point closing the switch. –

Engine Oil Pressure Gauge

ENGINE OIL PRESSURE GAUGE

GA3


OIL

PL2002 BE/RD

STANDARD

L I

G

S

GA2001 OE/BK GA2001 OE/BK

IG2006 BN/RD GD2000 WE PL2002 IGNITION 85 87

86 30 PR1

11 12 21 8 19 6 5 17 26 16 28 15 25 14 GA2001 OE/BK 13 22 9 10 7 4 3 2 NEGATIVE 1 WE PASS–THRU 29 STUD 20 18 23 27 24

CAB ACC FUSE GAUGE IG1001 YW

GA2001 OE/BK

OIL PRESSURE SENDER


GAUGE 10 A

1

Engine Oil Pressure Gauge Circuit


OTT0053

PL2002

GD2000 PL2002 BE/RD


H B C D G J K L M

S1 HEADLAMP SWITCH

F E A

S1 HEADLAMP SWITCH


S9 PANEL LTS DIMMER


145

Components Fuse — Gauge (Cab Accessory Fuse Panel) Gauge Gauge Lamp Headlight Switch Ignition Relay Panel Dimmer Switch (Optional) Sender (Oil Pressure — Variable Resistance) The engine oil pressure gauge reads in pounds per square inch (PSI).


146


Fuel Gauge

–

FUEL LEVEL GAUGE CIRCUIT GA2

FUEL S

GA2000

GD2000

FUEL LEVEL SENDER

L M

J K

D

C

F E A

S1 HEADLAMP SWITCH


G

STANDARD

S9 PANEL LTS DIMMER

H B


WE

BN/RD IG2006 BN/RD GD2000 WE GA2000 RD/BK

IG2006

S1 HEADLAMP SWITCH


FUEL LEVEL SENDER CONNECTOR



IG2006 BN/RD

PL2002

PL2002

GD2000

WE

GA2000 RD/BK

X U S L G F C T M V J D K N P A B E H R W

A

G

B

I

GA2000 RD/BK GD1001 WE

L

PL2002 BE/RD

IGNITION 85 87

86 30

IG1001 YW


OTT0054

PR1

1

Fuel Gauge Circuit Components Fuse — Gauge (Cab Accessory Fuse Panel) Gauge Gauge Lamp Headlight Switch Ignition Relay Panel Dimmer Switch (Optional) Sender (Fuel Level — Variable Resistance) The fuel level gauge displays quarter tank intervals. Maintenance manual Ottawa 4x2, 6x4


Low Air Warning Alarm

–

Components LOW AIR WARNING CIRCUIT

IG2006 BN/RD

CAB ACC FUSE GAUGE GAUGE IG2001 YW 10 A 1

Fuse — Gauge (Cab Accessory Fuse Panel)

IGNITION SWITCH

Ignition Relay

IGNITION 85 87

86

Low Air Alarm Buzzer

30 PR1

Low Air Switch

NEGATIVE PASS–THRU STUD GD2002 WE

Low Air Switch (Optional)

B

LOW AIR BUZZER

AS1000 GN/WE


GD2002 WE AS1000 GN/WE

B C A

BRAKE CONTROLS PANEL CONNECTOR LOW AIR SWITCH


OPTIONAL LOW AIR SWITCH

OTT0072

L

Low Air Warning Alarm Circuit


147

148


Speedometer (Optional)

–


STANDARD

S9 PANEL LTS DIMMER

S1 HEADLAMP SWITCH

GA1 SPEEDOMETER

TR-125 TN MD TRANS V HARNESS CAB CONNECTOR


GD2000 WE IG2006 BN/RD IGNITION

85 87

F L MH E J G C D K A B

ENGINE GAUGE AND WARNING PANEL CONNECTOR

86

CAB ACC FUSE GAUGE

30

GAUGE

IG2006

TR-125 TN

PL2002 BE/RD

B C D G J K L M

TR-125 TN

S


G

F E

DSO

I

IG2006 BN/RD A GD2000 WE H

PL2002 BE/RD

PL2002

L

PL2002

PR1

10 A

TR-125 TN – VEHICLE SPEED-SPEEDO

1

IG1001 YW

OTT0056

29 65 5 24 64 50 13 4 45 32 72 46 18 41 30 69 9 70 10 63 43 2 23 62 42 1 61 21 22 79 17 57 3 73 53 14 38 34 25 7 28 8 49 48 68 26 6 27 67 66 47 12 44 56 35 58 75 16 54 76 77 11 55 78 74 71 36 52 33 51 31 15 37 19 39 59 40 60 20 80

S1 HEADLAMP SWITCH

PL2002

GEN-4 ECU CONNECTOR

GEN-4 3000 TRANSMISSION ECU (TCM)

SPEEDOMETER CIRCUIT

Speedometer Circuit



149

Components Fuse — Gauge (Cab Accessory Fuse Panel) Gauge (Speedometer) Gauge Lamp Headlight Switch Ignition Relay Panel Dimmer Switch (Optional) Some tractor speedometers may also display the total distance traveled. The speedometer is affected by DIP switch settings, tire size, gear ratios and the source of pulse generation. –

Tachometer (Optional) WITH OPTIONAL DIMMER SWITCH

ENGINE TACHOMETER CIRCUIT STANDARD

GA11 GA4

S9 PANEL LTS DIMMER

L

PL2002 BE/RD

TACHOMETER

WATER I

G

S L

I

G

S

S1 HEADLAMP SWITCH

TA2000 PE

S1 HEADLAMP SWITCH


PL2002 BE/RD GA1000 BN/RD GD2000 WE

IGNITION 85 87

86 30

CAB ACC FUSE GAUGE GAUGE IG1001 YW

PL2002

10 A 1

TACHOMETER SIGNAL CAB EXTERIOR CONNECTOR TA2000 PE

PL2002 BE/RD


TA2000 PE

R ALTERNATOR

GROUND

PL2002

PR1

Tachometer Circuit



TACHOMETER SIGNAL DASH PANEL CONNECTOR

TA2000 PE


OTT0057

F E IG2006 BN/RD A GD2000 WE H B C D G J K L M


150


Components Alternator Fuse — Gauge (Cab Accessory Fuse Panel) Ignition Relay Gauge (Tachometer) Gauge Lamp (Tachometer) Gauge Lamp (Water Temperature) Gauge (Water Temperature) Headlight Switch Panel Dimmer Switch (Optional) The tachometer displays crankshaft revolutions per minute (RPM). –

Transmission Oil Temperature Gauge WITH OPTIONAL DIMMER SWITCH

TRANSMISSION OIL TEMPERATURE GAUGE CIRCUIT

STANDARD

S9 PANEL LTS DIMMER

GA8

L I

I G

TRANSMISSION GAUGE CONNECTOR

S

GA2006 PE/PK GD2000 WE AC2000 BN PL2002 BE/RD

TO MAIN CAB HARNESS

GA2006 PE/PK GD2000 WE AC2000 BN PL2002 BE/RD

IG2000 YW AC2000 BN

TRANSMISSION TEMPERATURE SENDER GA2006 PE/PK

GA2006 PE/PK B GD2000 WE PL2002 BE/RD A

A B

D C B A

TRANS TEMP GAUGE CONNECTOR

IGNITION SWITCH JUMPER CONNECTOR GD2000 WE B PL2002 BE/RD A AC2000 BN

A B

A C D B

IGNITION SWITCH CONNECTOR IG1000 RD/WE AC2000 BN ST2000 PK IG2000 YW

IG1000 RD/WE

A S

TRANS

OPTIONS PANEL JUMPER CONNECTOR NEGATIVE PASS-THRU STUD GD2000 WE

OPTIONS PANEL CONNECTOR

IGNITION SWITCH JUMPER-OPTIONS JUMPER

Transmission Oil Temperature Gauge Circuit



OTT0058

B

PL2002

IG1000 RD/WE

7 8 9 3 12 11 10 1 2 6 5 4

F

10 A 1

OPTIONS BULKHEAD CONNECTOR

A H B C D G J K L M

IGN SW

BA2000 RD

PL2002 BE/RD E


PL2002

CAB ACC FUSE IGNITION SWITCH

S1 HEADLAMP SWITCH

PL2002

S1 HEADLAMP SWITCH


151

Components Circuit Breaker — Ignition Switch (Cab Accessory Fuse Panel) Gauge Lamp Headlight Switch Ignition Switch Panel Dimmer Switch (Optional) Sender (Transmission Oil Temperature) Transmission Oil Temperature Gauge The transmission oil temperature gauge reads in degrees Fahrenheit (°F).


152


Voltmeter

–


VOLTMETER CIRCUIT

STANDARD

S9 PANEL LTS DIMMER

S1 HEADLAMP SWITCH

S1 HEADLAMP SWITCH

GA5

VOLT L

G

GD2000 WE IG2006 BN/RD

PL2002

86 30 PR1

CAB ACC FUSE GAUGE IG1001

10 A

1

C

A B

F

GAUGE

YW

PL2002 BE/RD G GD2000 WE M

85 87

J K

CAB CONTROLS PANEL CONNECTOR IGNITION

IG2006 BN/RD D

F L H

PL2002 BE/RD


PL2002 BE/RD

OTT0059

K L

M

D G J

H B C

ENGINE GAUGE & WARNING PANEL CONNECTOR F E A

PL2002

I

Voltmeter Circuit Components Fuse — Gauge (Cab Accessory Fuse Panel) Gauge Lamp Headlight Switch Ignition Relay Panel Dimmer Switch (Optional) Voltmeter The voltmeter detects the voltage at the accessory terminal on the ignition switch. Maintenance manual Ottawa 4x2, 6x4


9.3.4

153

Chassis Circuits


page –

CHASSIS BULKHEAD CONNECTOR 86

BA2000

RD

R3


AD1000

YW


AC1002 BN/RD CAB ACC FUSE AIR DRYER AIR DRYER 20 A

4

OTT0034

30

BUS BAR

CHASSIS OPTIONS

AC1002 BN/RD

85 87 87A

GD1001 WE


AIR DRYER CONNECTOR

AD1000 YW GD1001 WE

AIR DRYER

AIR DRYER CIRCUIT

Air Dryer Circuit Components Air Dryer Chassis Options Relay Circuit Breaker — Air Dryer (Cab Accessory Fuse Panel)


154


Cab Tilt Pump

–

TILT PUMP CIRCUIT BATTERIES

RD (BATTERY-TO-STARTER)

RD

BK

RD (BATTERY-TO-START SOL.)

RD

STARTER W/SOLENOID

RD (TILT SOL.-TO-TILT PUMP)

WE

TT2001


GD1001

WE

GD1001

WE

GN

GD1001

MID-FRAME CROSSMEMBER CONNECTOR

IGNITION 86

BA2000

RD

B TT2001 GN

C TT2000 BK

A TT1000 RD/BK

BK TT2000

RD

WE GD1001

TILT SWITCH HARNESS CONNECTOR

TILT PUMP CONTROL SWITCH

CAB ACC FUSE TILT TILT 5 A

OTT0035

30 PR1

BUS BAR

85 87

TT2001 GN TT1000 RD/BK TT2000 BK

TILT MOTOR -UP-

TT1000 RD/BK


GN

TILT SOL. -DN-

G U S L C F X V N D M B T P J W K R H A TT1000 E

RD/BK

TT2001

TT1000 RD/BK

2

Cab Tilt Pump Circuit Components Batteries Fuse — Tilt (Cab Accessory Fuse Panel) Ignition Relay Starter with Solenoid Tilt Pump Control Switch Tilt Pump Motor (Up) Tilt Solenoid (Down) Tilt Solenoid to Pump



9.3.5

155

Lighting Circuits (Cab and Chassis)

Backup Light and Alarm

page –

BACKUP LIGHT AND ALARM CIRCUIT

A

BU2000 BK/RD GD1001 WE

BACKUP ALARM CONNECTOR

B

BU2000 BK/RD GD1001 WE

BACKUP ALARM

BU2000 BK/RD

BU2000 BK/RD

BU2000 BK/RD

GD1001

WE

D E

BACKUP LIGHT

BU2000 BK/RD GD1001

WE

B


R H A E

J W K

B T P

L C F X V N D M

G U S

TAIL LIGHTS CONNECTOR


IGNITION 85

86

87

30 PR1

CAB ACC CIRCUIT BREAKER REVERSE REVERSE 2

BU1000

7.5 A

REVERSE 85

86 30

BU1000

BK OTT0065

87 87A

BK

IG1001 YW

R5

Backup Light and Alarm Circuit Components Backup Alarm Backup Lamp Circuit Breaker — Reverse (Cab Accessory Fuse Panel) Ignition Relay Reverse Relay Transmission Case Ground The backup lamp illuminates and the alarm sounds when the transmission is shifted to reverse.


156


Beacon/Strobe Light

–

UPPER CAB CONNECTOR

EL2001 YW/WE GD2001 WE

B A C D F E


BEACON LIGHT CIRCUIT BEACON/ STROBE LIGHT

EL2001 YW/WE GD2001 WE

EL1000 BN/BK

EL2001 YW/WE

OPTION FLOOD BEACON LIGHT SWITCH SWITCH

EL1000 BN/BK

EL2001 YW/WE

C B A

FLOOD & BEACON LIGHT CONNECTOR

ACC #2 86

85 87

30 PR2

CAB ACC FUSE EXTERIOR LIGHTING EXT LIGHTING 25 A

1

Beacon/Strobe Light Circuit


OTT0066

AC1001 BN


157

Components Accessory Relay #2 Beacon/Strobe Lamp Fuse — Exterior Lighting (Cab Accessory Fuse Panel) Beacon Light Switch (Optional) Flood Light Switch The flood light switch is mounted on the instrument panel. –

Clearance Lights REMOTE POSITIVE STUD

TRAILER CONNECTOR

PL2001 BE/BK


TRAILER

GD2001 WE

85 LIGHTS 86 87 30 87A R1

BUS BAR

PL1000 OE/WE

BA2002

PL2000 BE

PARK LTS 3

HEADLIGHT SWITCH CONNECTOR

PL1000 OE/WE

BA2000 RD


OTT0067

1 2 3 4 5 6 7

CLEARANCE LIGHT CIRCUIT

PL2000 BE D C A B


CAB ACC FUSE PARKLIGHTS 10 A

PL1000 OE/WE


S1 HEADLAMP SWITCH

UPPER CAB CONNECTOR

PL2000 BE

10 A

BA2002 RD

PL2000 BE

BK

GD2001 WE

BN

B A C D F E

10 A MARKER ID

PL2000 BE

TAIL/CLRNC

BN – TAIL/RR CLRNC/LIC

PL2001 BE/BK

PL2000 BE

TRAILER BREAKERS

GD2001 WE

CLEARANCE LIGHTS

BK – SIDE MRKR/ID

PL2001 BE/BK


Clearance Lights Circuit Components Circuit Breaker — Parking Lights (Cab Accessory Fuse Panel) Circuit Breaker — Marker/ID Lights (Trailer Breakers) Circuit Breaker — Tail/Clearance Lights (Trailer Breakers) Cab Clearance Lamps Headlight Switch Trailer Lights Relay Double Face Turn/Marker Lights are standard equipment on vehicles that meet FMVSS and CMVSS requirements.


158


Daytime Running Lights (Optional)

–

LH HEADLIGHT

LH HEADLIGHT CONNECTOR

HL2002 – BE/WE HL2001 – BE/BK GD2002 – WE

RD – HI BEAM BK – LO BEAM GN – GROUND

RH HEADLIGHT CONNECTOR

DR2002 – RD HL2002 – BE/WE HL2001 – BE/BK GD2002 – WE DR2002 – RD DR2000 – BE

DR2002 – RD

DAYTIME RUNNING LIGHTS CIRCUIT

A B C

7 8 9 3 12 11 10 1 2 6 5 4

OPTIONS BULKHEAD CONNECTOR DR2002 – RD IG1001 YW

IGNITION 85 87

86 30 PR1

IG1001 YW

CAB ACC FUSE D.R.L. DRL 10 A

F E D C B A

4

DAYTIME RUNNING LIGHTS MODULE (WE) POWER TO HEADLIGHT (RD) BATTERY (BK) GROUND (GN) LOW BEAM (GN) HI BEAM (BE) IGNITION

DAYTIME RUNNING LIGHTS CONNECTOR

Daytime Running Lights Circuit Components Daytime Running Lights Module Fuse — Daytime Running Lights (Cab Accessory Fuse Panel) Head Lamps Ignition Relay


OTT0060

HL2002 – BE/WE HL2001 – BE/BK DR2000 – BE

BUS BAR

HI BEAM – RD A LO BEAM – BK B GROUND – GN C

RH HEADLIGHT


159

Dome Light

–

DOME LIGHT CIRCUIT GD2001 WE CL1000 BN/RD

ACC #2 85

86

87

DOME LIGHT

30

GD2001 WE

CL1000 BN/RD

PR2

F

E

D

A

C

GD2001 WE

1

NEGATIVE PASS-THRU STUD OTT0061

10 A

GD2001 WE

CAB ACC FUSE LIGHTING CAB LIGHTING

CL1000 BN/RD

AC1001 BN

B

UPPER CAB CONNECTOR

Dome Light Circuit Components Accessory Relay #2 Dome Lamp with Switch Fuse — Cab Lighting (Cab Accessory Fuse Panel) The lamp On/Off switch is on the dome light fixture. –


160


Fifth-Wheel Control Refer to Transmission Shifter. –

Flood Light Components FLOOD LT SWITCH

FLOOD LIGHT CIRCUIT

Flood Light

GD2001 WE

EL2000 BE/BK EL2000 BN/BK C

B A C D F E

EL2000 BE/BK

NEGATIVE PASS–THRU STUD UPPER CAB CONNECTOR

Flood Light Switch Fuse — Exterior Lighting (Cab Accessory Fuse Panel)

EL2000 BE/BK B EL1000 BN/BK A

FLOOD & BEACON LIGHT CONNECTOR

EL2000 BE/BK

Accessory Relay #2

FLOOD LIGHT

CAB ACC FUSE EXTERIOR LIGHTING AC1001 BN

EXT LIGHTING 25 A

EL1000 BN/BK

1

86 30 PR2

OTT0074

ACC #2 85 87

Flood Light Circuit –



161

Headlights TURN SIGNAL SWITCH CONNECTOR

HEADLIGHT CIRCUIT

YW GN RD GY BK GY/BK WE WE

TURN SIG & DIMMER SW

LEFT HAND HEADLIGHT CONNECTOR

BUS BAR

HEAD LTS 2

HL2001 BE/BK HL2002 BE/WE


A B C

RD-HI BEAM BK-LO BEAM GN-GROUND

GD2002 WE GD2002 WE

R4

HL2000 BE/RD CAB ACC FUSE HEADLIGHTS


HL2001 BE/BK HL2002 BE/WE GD2002 WE HL2001 BE/BK HL2002 BE/WE

HI-LOW 85 HEAD LTS 86 87 30 87A

RIGHT HAND HEADLIGHT CONNECTOR

HL2001 BE/BK HL2002 BE/WE GD2002 WE

HI BEAM-RD A LO BEAM-BK B GROUND-GN C

B

D

HL2000 BE/RD C HL1000 OE A

BA2002 RD

RH HEADLIGHT

LH HEADLIGHT

HL2001 BE/BK HL2002 BE/WE


Headlight Circuit Components Circuit Breaker — Head Lights (Cab Accessory Fuse Panel) Headlamps Headlight Relay (High/Low) Headlight Switch Turn Signal and Dimmer Switch –

Marker Lights Refer to Clearance, Marker and Tail Lights. –

Panel Lighting Refer to Transmission Shifter. –

Strobe Light Refer to Beacon/Strobe Light. –

Tail Lights Refer to Turn Signal, Tail, Brake Lights and Emergency Flasher.


OTT0062

HL2000 BE/RD HL1000 OE

HL2003 WE/BK


15 A

HL2003 WE/BK GD2000 WE NEGATIVE PASS-THRU STUD

S1 HEADLAMP SWITCH

REMOVE POSITIVE STUD

A B C D E F G H

162


Trailer Auxiliary Power

–

TRAILER AUX SWITCH POWER RELAY B19 86

85 87

30

AB2000 RD

TS2000 IG2000


IG2000 YW AC2000 BN

TRIAXLE SWITCH CONNECTOR IGNITION SWITCH JUMPER


IGNITION SWITCH JUMPER-ABS HARNESS

TS2001 BN/WE

B A

87A

B A

TS2000 BN/BK IG2000 YW

A B

S17 TRAILER AUX SWITCH

NEGATIVE PASS THRU STUD

GD2004 WE TS2001 BN/WE


TRAILER BREAKER TS2001 BN/WE

TRBK 15A

Trailer Auxiliary Power Circuit Components Circuit Breaker — TRBK (Trailer Breaker) Ignition Switch Jumper Ignition Switch Jumper (ABS Harness) Relay — B19 (Trailer Auxiliary Switch Power Relay) Trailer Auxiliary Switch Triaxle Switch Connector The trailer auxiliary switch is not used with ABS.


OTT0068

TRAILER AUXILIARY POWER


163

Transmission Shifter, Fifth-Wheel Control and Panel Lighting

–

WITH OPTIONAL DIMMER SWITCH STANDARD

TRANSMISSION SHIFTER/5TH WHEEL CONTROL & PANEL LIGHTING

S9 PANEL LTS DIMMER

MD TRANS BULKHEAD CONNECTOR

GEN-4 3000 LEVER SHIFTER

MD TRANS SHIFTER CONNECTOR

LIGHT BAR CONNECTOR FOR HEATER CONTROL LHS

LIGHT BAR CONNECTOR FOR HEATER CONTROL RHS

GD2000

GD2000 WE

PL2002

PL2002 BE/RD

LIGHT BAR CONNECTOR FOR FAN CONTROL

GD2000 WE LIGHT BAR

PL2002 BE/RD

LIGHT BAR CONNECTOR FOR OPTION SWITCHES E L H D J K F PL2002 BE/RD G M GD2000 WE A B C

PL2002 BE/RD

PL2002 BE/RD



PL2002 BE/RD – DIMMER INPUT



GD2000 WE

PL2002 BE/RD PL2002 BE/RD

PL2002 BE/RD


CAB BULKHEAD CONNECTOR 5TH WHEEL CONTROL CONNECTOR PL2002 BE/RD GD2002 WE NEGATIVE PASS-THRU STUD

Transmission Shifter, Fifth-Wheel Control and Panel Lighting Circuit Components Headlight Switch Lamps (2 — Fifth-Wheel Control) Light Bar — Heater Control LHS Light Bar — Heater Control RHS Light Bar — Fan Control Light Bar — Option Switches Panel Dimmer Switch (Optional)


5TH WHEEL CONTROL

OTT0063

MD TRANS V HARNESS CAB CONNECTOR (IN CAB AT ‘B’ PILLAR)

9 10 5 13 12 11 3 1 8 15 14 16 7 2 4 6

LIGHT BAR


PL2002 PL2002 BE/RD

M L F H B A K C E D J G

PL2002


12 35 11 22 21 5 31 14 4 3 33 34 13 1 2 32 24 15 25 30 40 18 8 37 17 36 26 10 16 27 20 23 28 39 38 19 7 29 6 9

LIGHT BAR

S1 HEADLAMP SWITCH

LIGHT BAR

S1 HEADLAMP SWITCH

164


The electroluminescent lamp illuminates when the ignition switch is in the Run position. It operates independently of the headlight switch.

Turn Signal, Tail, Brake Lights and Emergency Flasher

–


PL1000 OE/WE


TURN SIGNAL SWITCH CONNECTOR A B C D E F G H

TL2000 TN/WE TL2001 TN TL2002 GN TL2003 YW TL2004 GN/WE SL2000 BK

GD2000 WE

TL2001 TN

TL2000 TN/WE

L

TL2002 GN

FLASHER B

YW GN RD GY BK GY/BK WE WE

PL1000 OE/WE

TL1000 OE/BK

30 A 4

TURN SIG & DIMMER SW

D C A B

PL2000 BE

20 A 1

FLASHER

PL2000 BE

TL2001 TN TL2001 TN

GD2000 WE

GD2000 WE

TL2002 GN

CAB ACC FUSE STOPLIGHTS BA2002 RD STOP LTS




BUS BAR


GD2000 WE

LH TURN

E L H D J K F G M A B C


GD2000 WE

TL2002 GN

RH TURN

PL1000 OE/WE

S1 HEADLAMP SWITCH

TL2002 GN TL2001 TN PL2000 BE BU2000 BK/RD

TL2003 YW TL2004 GN/WE SL2000 BK


X U S L G F C T M V J D K N P A B E H R W

BU2000 BK/RD

CAB BULKHEAD CONNECTOR TL2002 GN TL2001 TN

SL1000 OE/RD SL2000 BK

TURN SIGNAL, TAIL, BRAKE LIGHTS & EMERGENCY FLASHER

CAB ACC FUSE STOPLIGHTS REMOTE POSITIVE STUD

BA2002 RD

STOP LTS 20 A 1

Turn Signal, Tail, Brake Lights and Emergency Flasher Circuit — Part A Maintenance manual Ottawa 4x2, 6x4



TL2004 GN/WE PL2000 BE

GD1001 WE

RH FRONT TURN/PARK

GD1001 WE SL2000 BK BU2000 BK/RD TL2004 GN/WE

CAB ACC FUSE PARKLIGHTS PARK LTS

PL2000 BE TL2002 GN PL2000 BE PL2000 BE TL2002 GN

TL2001 TN

PL2000 BE TL2001 TN

TL2002 GN TL2001 TN

TL2004 GN/WE PL2000 BE GD1001 WE BU2000 BK/RD

BACK-UP LIGHT

GD1001 WE

SL2000 BK STOPLIGHT CONNECTOR D C E B A

GD1001 WE TL2003 YW PL2000 BE

LH REAR STOP/TURN/TAIL

TAIL LIGHTS CONNECTOR

SL2000 BK BU2000 BK/RD TL2004 GN/WE TL2003 YW

GD1001 WE

(NOT USED WHEN STOP/TURN/TAIL LIGHT IS COMBINED)

BU2000 BK/RD TL2004 GN/WE GD1001 WE TL2003 YW PL2000 BE

TL2003 YW

10 A 3

LH FRONT TURN/PARK

GD1001 WE

TL2002 GN PL2000 BE GD1001 WE

BA2002 BUS BAR


PL1000 OE/WE

RH REAR STOP/TURN/TAIL

GD1001 WE

PL2000 BE TL2002 GN REMOTE POSITIVE STUD BA2002 RD

165

PL2000 BE BU2000 BK/RD

TL2003 YW TL2004 GN/WE SL2000 BK REVERSE

CAB ACC FUSE REVERSE

86 30

BU1000 BK

R5

REVERSE

IG1001 YW

7.5 A 2

85 87 87A

IGNITION

86 30

PR1

CIRCUIT BREAKERS TL2002 GN TL2001 TN

RH TURN 10 A LH TURN

GN YW

10 A

TL2002 GN TL2001 TN CAB ACC FUSE STOPLIGHTS SL1000 OE/RD SL2000 BK SL2000 BK

STOP LTS 15 A

RD YW – LH TURN RD – STOP GN – RH TURN

SL2000 BK

1 2 3 4 5 6 7

SL1000 OE/RD STOP LIGHT SWITCH

TRAILER CONNECTOR

Turn Signal, Tail, Brake Lights and Emergency Flasher Circuit — Part B Maintenance manual Ottawa 4x2, 6x4

OTT0064

85 87 87A

166


Components Backup Lamp Circuit Breaker — Flasher (Cab Accessory Fuse Panel) Circuit Breaker — Parking Lights (Cab Accessory Fuse Panel) Circuit Breaker — Reverse (Cab Accessory Fuse Panel) Circuit Breaker — Stop Lights (Cab Accessory Fuse Panel) Circuit Breaker — Left Turn (Trailer Circuit Breakers) Circuit Breaker — Right Turn (Trailer Circuit Breakers) Circuit Breaker — Stop Lights (Trailer Circuit Breakers) Flasher Headlight Switch Ignition Relay Reverse Relay Stop Light Switch Stop/Turn/Tail Lamps (Right and Left) Turn Signal and Headlight Dimmer Switch Turn Indicator Lamps (Instrument Panel, Right and Left) Turn Signal/Parking Lamps (Front, Right and Left) Double-faced Turn/Marker Lights are standard equipment on vehicles manufactured to FMVSS and CMVSS specifications.


Maintenance Manual Ottawa 4x2, 6x4

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